ECE5320 Mechatronics

Assignment#01: Literature Survey on Sensors and Actuators

Topic: Hall Effect Rotary Encoders

Prepared by: Mike Tyger
Dept. of Electrical and Computer Engineering Utah State University

3/06/2009

Slide-2

Outline
Reference List Explore Further Major applications Overview Basic working principle Typical Application Major Specifications Limitations

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-3

Reference list
Sensors, Understanding Integrated Hall Effect Rotary Encoders, www.sensorsmag.com/sensors/article/articleDetail.js p?id=383802. EDN, Rotary encoder mates with digital potentiometer , www.edn.com/article/CA278837.html EDN, Automotive Hall-effect rotary-position sensor uses novel flux-concentrator technology www.edn.com/article/CA6492443.html
11/11/2013
ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-4

To explore further (survival pointers of web references etc)

http://www.austriamicrosystems.com/eng/Products/MagneticEncoders/Rotary-Encoders
Leading manufacturer of hall effect rotary encoders. Data sheets for complete product line

http://www.everightsensors.com/index.shtml
Manufacturer of rotary encoders

http://en.wikipedia.org/wiki/Hall_effect
In depth discussion of the Hall effect

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-5

Major Applications
Measure:
Angular Velocity Angular Position Magnetic Field Strength

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-6

Overview
A linear Hall sensor generates a DC output voltage proportional to the strength of an applied magnetic field. The output of a Hall sensor is a sine wave with a with a frequency of one cycle per revolution when the sensor is placed near a rotating diametrically magnetized magnet. Multiple Hall sensors can be used for accurate angle measurements.
11/11/2013
ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-7

Overview - General
Voltage output of Hall sensor varies with the strength and pole of the magnetic field.

http://www.sensorsmag.com/sensors/data/articlestandard//sensors/442006/383802/i1_t.jpg

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-8

Overview Angular position

Multiple Hall sensors in an array are used to accurately determine angular position

http://www.sensorsmag.com/sensors/data/articlestandard//sensors/442006/383802/i2_t.jpg

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-9

Advantages
Small Lightweight Low power Non-Contact Long life

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-10

Advantages
High degree of accuracy Simplified manufacturing compared to optical encoder Programmable zero-position

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-11

Principle Field Strength

http://www.sensorsmag.com/sensors/data/articlestandard//sensors/442006/383802/i10_t.jpg

The 4 Hall sensors in the array each measure a different magnetic field strength as the magnet rotates on the axis.
11/11/2013
ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-12

Principle Sine and Cosine Signals

The output of each sensor is a Sine or Cosine wave = peak amplitude

= magnet rotational angle relative to the sensor

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-13

Principle Differential Signals

Differential amplification of signals from opposite sensors in the array results in a sine and a cosine wave which can be interpreted by the CORDIC algorithm

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-14

Principle CORDIC Algorithm

A CORDIC (coordinate rotation digital computer) transforms the differential signal into angle and magnitude A= measured angle = magnet rotational angle relative to the sensor = peak amplitude The final equation shows that the magnetic field amplitude can be eliminated from the calculation, resulting in the elimination of the effects of stray magnetic fields.

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-15

Principle 360 Measurement

http://www.sensorsmag.com/sensors/data/articlestandard//sensors/442006/383802/i7_t.jpg

The output of the CORDIC can accurately determine the angular position of the magnet relative to the sensors.
11/11/2013
ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-16

Design Issues
Resolution Accuracy Phase Error Offset Errors ADC nonlinearities Magnet nonlinearities

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-17

Resolution and Accuracy

Resolution
Resolution is the smallest angle step that can be measured by the sensor. Angle changes smaller than the resolution will not be read. Resolution is mainly determined by the resolution of the ADC and the calculation depth of the CORDIC.

Accuracy
Accuracy is the deviation between the indicated angle and the actual angle.

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-18

Phase and Offset Errors

Phase Errors
The Hall sensor signals must be phase-shifted by exactly 90, propagation delays in the sensors can result in significant error.

Offset Errors
Offset errors occur primarily in the Hall element and are due to poor transistor matching of the components in the analog signal path.

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-19

Nonlinearities
ADC nonlinearities
A High-performance ADC is required since ADC nonlinearity cannot be compensated for.

Magnet nonlinearities
The Hall elements of the array must be in the linear range of the magnetic field. This range is larger for larger diameter magnets but the field distribution curve is more shallow, resulting in a smaller differential signal.

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-20

Typical Application

http://news.thomasnet.com/images/medium/499/499091.jpg

Rotary encoder in industrial housing

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-21

Major Specifications
360 contactless angular position encoding User programmable zero position High speed: up to 30,000rpm Direct measurement of magnetic field strength allows exact determination of vertical magnet distance Wide magnetic field input range: 20 ~ 80mT Wide temperature range: -40C to 125C

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-22

Limitations
Highly susceptible to stray magnetic fields
Requires precise assembly Possible need for magnetic shielding

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-23

Limitations
Sensors must be placed very accurately around the centerline of the rotational axis.
Multiple sensors are typically contained in a single package Sensor must be very accurately placed on PCB Small tolerances of sensor PCB mounting fixtures can increase cost

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-24

Other Considerations
Robustness
The non-contact nature of a magnetic encoder makes it fairly robust. The CORDIC can be used to eliminate the effect of stray magnetic fields

Hall effect sensors are used in a wide variety of applications

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

Slide-25

Other Considerations
The ratio of sensor accuracy to sensor cost is very good for a hall effect rotary encoder

11/11/2013

ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators