A hall sensor detection device and method

Abstract

The application discloses a kind of hall sensor detection device and method, effectively reach the effect of early performance degradation of hall sensor accurate early warning, including: magnetic field induction unit, for detecting the first magnetic field intensity around measured object and generating first magnetic field signal;Reference magnetic field detection unit, its setting position is adapted to the magnetic field induction unit, for detecting the second magnetic field intensity of the area where the magnetic field induction unit is and generating second magnetic field signal;Reference magnetic field generation unit, for generating the reference magnetic field of known intensity in the area where the magnetic field induction unit is;Signal processing and control unit are electrically connected with the magnetic field induction unit, the reference magnetic field detection unit and the reference magnetic field generation unit respectively;The application is novel in structure, ingenious in conception, easy and simple to operate, effectively realizes from passive alarm to predictive maintenance upgrade, improves the accuracy of system decision, reduces the dependence on external calibration.

Description

Technical Field

[0001] This invention belongs to the field of Hall sensor detection technology, and relates to a Hall sensor detection device and method. Background Technology

[0002] Hall effect sensors, especially Hall current sensors, are core sensing components in modern industrial automation, new energy vehicles, renewable energy, and smart grids. They are responsible for real-time, isolated, and accurate measurement of current, forming the basis for precise control and system protection. However, in practical applications, the reliability of Hall effect sensors faces significant challenges due to their semiconductor characteristics and operating principle.

[0003] Currently, the mainstream methods for diagnosing Hall effect sensor faults focus on monitoring their output signals. A common approach is to determine that the sensor has failed when its output voltage signal is detected to be zero or outside a preset range, such as due to an open power supply, a short circuit in the signal output, or damage to the internal chip, thereby triggering the system's protection mechanism. While this method can detect obvious hard faults, it has a fundamental flaw: it cannot distinguish between a "true zero current signal" and a "zero output signal caused by sensor failure."

[0004] Specifically, in applications such as motor control, when the system is in standby or light-load mode, the measured current is indeed zero, and the actual output of the Hall sensor should also be zero. If a fault is mistakenly identified simply because the output is zero, it will lead to unnecessary system shutdowns or false alarms, severely impacting the normal operation and availability of the equipment. On the other hand, sensors may experience gradual performance degradation due to factors such as aging, stress, or electromagnetic interference, resulting in sensitivity decay and zero-point drift. Traditional threshold judgment methods struggle to identify such "soft faults" in their early stages, often leading to serious accidents by the time the system exhibits obvious abnormalities.

[0005] While some existing technologies have attempted to improve diagnostic reliability by adding redundant sensors or complex algorithms, these approaches either significantly increase system cost and size or rely on idealized models, lacking robustness under real-world, variable operating conditions. Therefore, a Hall sensor detection device and method are needed to address these issues, enabling real-time and accurate assessment of the Hall sensor's operating status without significantly increasing costs. Summary of the Invention

[0006] To address the aforementioned problems, this invention proposes a Hall sensor detection device and method, which effectively solves the problems in the prior art.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] A Hall sensor detection device, comprising:

[0009] A magnetic field sensing unit is used to detect the strength of a first magnetic field around the object being measured and to generate a first magnetic field signal.

[0010] A reference magnetic field detection unit is positioned to match the magnetic field sensing unit and is used to detect the second magnetic field strength in the area where the magnetic field sensing unit is located and generate a second magnetic field signal.

[0011] A reference magnetic field generating unit is used to generate a reference magnetic field of known strength in the region where the magnetic field sensing unit is located;

[0012] The signal processing and control unit is electrically connected to the magnetic field sensing unit, the reference magnetic field detection unit, and the reference magnetic field generating unit, respectively.

[0013] The signal processing and control unit is configured as follows:

[0014] Receive the first magnetic field signal and the second magnetic field signal;

[0015] Based on the comparison results of the first magnetic field signal and the second magnetic field signal, the working state of the magnetic field sensing unit is determined;

[0016] The reference magnetic field generating unit is controlled to operate, and during the application of the reference magnetic field, the parameters of the magnetic field sensing unit are calibrated based on the first magnetic field signal and the second magnetic field signal.

[0017] Preferably, the reference magnetic field generating unit is a micro coil or a soft magnetic material magnetization unit, which is configured to generate a stable or transient reference magnetic field of a preset intensity in the area where the magnetic field sensing unit is located in calibration mode.

[0018] Preferably, the signal processing and control unit is configured to determine the operating state of the magnetic field sensing unit in the following manner:

[0019] In response to each signal sampling, the first magnetic field strength calculated based on the first magnetic field signal and the second magnetic field strength calculated based on the second magnetic field signal are compared;

[0020] If the absolute value of the difference between the two exceeds the first preset threshold, it is determined that the magnetic field sensing unit has experienced performance degradation.

[0021] If the absolute value of the difference between the two exceeds a second preset threshold greater than the first preset threshold, then the magnetic field sensing unit is determined to have suffered a serious failure.

[0022] Preferably, the signal processing and control unit is further configured to perform graded safety response actions when performance degradation or serious failure is determined to occur, including issuing a warning signal, degrading operation, or disconnecting the drive circuit.

[0023] Preferably, the signal processing and control unit is configured to calibrate the parameters of the magnetic field sensing unit in the following manner:

[0024] While controlling the reference magnetic field generating unit to generate a reference magnetic field of known intensity, the first calibration output signal of the magnetic field sensing unit and the second calibration output signal of the reference magnetic field detection unit are simultaneously acquired.

[0025] Based on the second calibration output signal and the known sensitivity of the reference magnetic field detection unit, the true calibration magnetic field strength is calculated.

[0026] Based on the actual calibration magnetic field strength and the first calibration output signal, the real-time sensitivity calibration coefficient and / or zero-point offset calibration value of the magnetic field sensing unit are calculated.

[0027] Preferably, the signal processing and control unit is further configured to store the calculated real-time sensitivity calibration coefficient and / or zero-point offset calibration value in a non-volatile memory, and to use it to perform real-time compensation on the first magnetic field signal subsequently output by the magnetic field sensing unit.

[0028] Preferably, the triggering conditions for parameter calibration include at least one of the following: system power-on initialization, detection that the system is in a no-load idle state, temperature change exceeding a set value, and receiving an external calibration command.

[0029] A Hall sensor detection method, applied to the aforementioned Hall sensor detection device, the method comprising:

[0030] The second magnetic field strength in the area where the magnetic field sensing unit is located is detected in real time by the reference magnetic field detection unit, and a second magnetic field signal is generated.

[0031] The magnetic field sensing unit detects the strength of a first magnetic field around the object being tested and generates a first magnetic field signal.

[0032] Based on the comparison results of the first magnetic field signal and the second magnetic field signal, the working state of the magnetic field sensing unit is determined;

[0033] The reference magnetic field generating unit is controlled to generate a reference magnetic field of known strength;

[0034] During the application of the reference magnetic field, the parameters of the magnetic field sensing unit are calibrated based on the first magnetic field signal and the second magnetic field signal.

[0035] Preferably, determining the operating state of the magnetic field sensing unit includes:

[0036] In response to each signal sampling, the first magnetic field strength calculated based on the first magnetic field signal and the second magnetic field strength calculated based on the second magnetic field signal are compared;

[0037] If the absolute value of the difference between the two exceeds the first preset threshold, it is determined that the magnetic field sensing unit has experienced performance degradation.

[0038] If the absolute value of the difference between the two exceeds a second preset threshold greater than the first preset threshold, then the magnetic field sensing unit is determined to have suffered a serious failure.

[0039] Preferably, the parameter calibration of the magnetic field sensing unit includes:

[0040] During the application of the reference magnetic field, the first calibration output signal of the magnetic field sensing unit and the second calibration output signal of the reference magnetic field detection unit are acquired simultaneously.

[0041] Based on the second calibration output signal and the known sensitivity of the reference magnetic field detection unit, the true calibration magnetic field strength is calculated.

[0042] Based on the actual calibration magnetic field strength and the first calibration output signal, the real-time sensitivity calibration coefficient and / or zero-point offset calibration value of the magnetic field sensing unit are calculated.

[0043] The sensitivity of the magnetic field sensing unit is corrected using the real-time sensitivity calibration coefficient, and zero-point correction is performed using the zero-point offset calibration value.

[0044] Compared with the prior art, the present invention has the following beneficial effects:

[0045] This invention features a reference magnetic field detection unit. By setting up an independent reference magnetic field detection unit and performing real-time, continuous cross-validation and consistency analysis with the output of the main magnetic field sensing unit, it can sensitively detect minute deviations between the two signals. When the deviation exceeds a first preset threshold, the system can determine that the main sensor has experienced performance degradation and issue an early warning. This allows maintenance personnel or the control system to take maintenance measures before the sensor completely fails, achieving predictive maintenance and avoiding unplanned downtime and production losses caused by sudden sensor failure. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the Hall sensor detection device of the present invention.

[0047] Figure 2 This is a schematic diagram of the detection process of the Hall sensor detection method of the present invention. Detailed Implementation

[0048] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0049] The following is in conjunction with the appendix Figures 1 to 2 The specific embodiments of the present invention will be described in further detail below.

[0050] Example 1:

[0051] This embodiment provides a Hall sensor detection device, offering a multi-layered, self-diagnostic, and calibrable detection system. The device mainly includes a magnetic field sensing unit, a reference magnetic field detection unit, a reference magnetic field generating unit, and a signal processing and control unit.

[0052] Magnetic field sensing unit: In this embodiment, the magnetic field sensing unit is the main Hall current sensor to be detected. It is used to detect the magnetic field generated by the current conductor being measured, such as a three-phase motor drive line, and outputs a corresponding first voltage signal, i.e., a first magnetic field signal.

[0053] A reference magnetic field detection unit is positioned adjacent to or integrated within the same package as the magnetic field sensing unit to ensure it can sense the magnetic field in the area where the magnetic field sensing unit is located, thus ensuring the sensing of the same magnetic field environment. Preferably, the reference magnetic field detection unit is positioned directly below the main Hall current sensor to detect the absolute magnetic field strength in its area and output a corresponding second voltage signal, i.e., a second magnetic field signal. The reference magnetic field detection unit itself is a magnetic field sensor with known sensitivity, possessing long-term accuracy and stability far exceeding that of the magnetic field sensing unit. Its sensitivity is precisely calibrated at the factory and stored in the signal processing and control unit. During the expected lifespan of the device, the variation in its sensitivity is designed to be negligible, thereby providing a reliable independent magnetic field reference for the magnetic field sensing unit.

[0054] The reference magnetic field generating unit is crucial for achieving online self-calibration. In a preferred embodiment, the reference magnetic field generating unit is a miniature coil integrated within the package, configured to generate a stable reference magnetic field of preset strength in the area where the magnetic field sensing unit and the reference magnetic field detection unit are located during calibration mode. This miniature coil is driven by a signal processing and control unit.

[0055] Signal processing and control unit: This unit typically consists of a microcontroller (MCU) and its peripheral circuitry, such as a high-precision ADC, DAC, and non-volatile memory. It is electrically connected to the aforementioned magnetic field sensing unit, reference magnetic field detection unit, and reference magnetic field generating unit, and is responsible for the overall system control, signal processing, algorithm execution, and decision-making.

[0056] The operating modes of this device are controlled by the signal processing and control unit program, and are mainly divided into the following types:

[0057] 1. Normal operation and real-time diagnostic mode

[0058] In this mode, the signal processing and control unit continuously and synchronously acquires the first magnetic field signal from the magnetic field sensing unit and the second magnetic field signal from the reference magnetic field detection unit. The internal program of the signal processing and control unit compares the magnetic field strength calculated based on these two signals in real time. If the deviation exceeds a first preset threshold (e.g., 3% of full scale), it is determined that the main Hall sensor has deteriorated, i.e., the magnetic field sensing unit has deteriorated, and an early warning is issued. If the deviation further expands to a second preset threshold (e.g., 10% of full scale), it is determined to be a serious failure, and safety actions such as cutting off the drive circuit are executed. This process achieves continuous multi-parameter fusion safety verification that far exceeds simple on / off judgment.

[0059] 2. Online self-calibration mode

[0060] This mode is the core of achieving high precision and durability. Calibration can be triggered by system power-on, sudden temperature changes, idle state, or external commands.

[0061] Upon triggering, the signal processing and control unit controls the miniature coil of the reference magnetic field generating unit to operate, applying a precise calibration current I. cal This generates a known strength of B. cal A stable reference magnetic field.

[0062] During the period when the reference magnetic field is stable, the signal processing and control unit acquires data synchronously:

[0063] The first calibration output signal V of the magnetic field sensing unit hall cal .

[0064] The second calibration output signal V of the reference magnetic field detection unit ref cal .

[0065] Next, the signal processing and control unit performs the following calculations:

[0066] Calculate the true magnetic field: using the known sensitivity K of the reference magnetic field detection unit. ref The actual calibration magnetic field strength B was calculated. real =V ref cal / K ref Since the magnetic field generated by the reference magnetic field generating unit is known, this step also verifies the normal operation of the reference magnetic field detection unit.

[0067] Calculate calibration parameters:

[0068] Real-time sensitivity K hall cal =V hall cal / B real .

[0069] Zero offset V offset : can apply a zero calibration magnetic field (I cal The data was collected when the value was 0.

[0070] Update and compensation: K hall real and V offset The data is stored in non-volatile memory. In all subsequent measurements, the signal processing and control unit uses the new parameters to compensate for the raw output of the magnetic field sensing unit in real time.

[0071] Final precise value = (original output - V) offset )×(nominal sensitivity / K hall real )

[0072] 3. Security Protection Mode

[0073] This mode is linked to diagnostic results. When the signal processing and control unit determines performance degradation, it can control the system to operate at a lower performance level and report an early warning; when a serious failure is determined, it immediately executes a safety redundancy strategy or disconnects the main circuit, and reports to the host computer via the safety bus, fully complying with functional safety standards.

[0074] Example 2:

[0075] This embodiment provides a Hall sensor detection method, which is applied to the hardware platform described in the above device embodiment.

[0076] The method includes the following steps:

[0077] S101: Real-time detection and signal generation. The second magnetic field strength in the area where the magnetic field sensing unit is located is detected in real time by the reference magnetic field detection unit, and a second magnetic field signal is generated; at the same time, the first magnetic field strength around the object being measured is detected by the magnetic field sensing unit, and a first magnetic field signal is generated.

[0078] S102: Operating Status Determination (Multi-parameter Fusion Diagnosis). The signal processing and control unit determines the operating status of the magnetic field sensing unit based on the comparison results of the first magnetic field signal and the second magnetic field signal. Specifically, it continuously compares the magnetic field strength calculated from the two signals respectively, and determines whether it is normal, degraded, or severely failed based on whether the deviation exceeds a preset threshold.

[0079] S103: Trigger calibration. When preset trigger conditions are met, such as power-on, idle, excessive temperature change, or external command, the online self-calibration process is initiated. The temperature change setpoint is determined based on the thermal characteristics of the sensor chip.

[0080] S104: Apply a reference magnetic field. Control the operation of the reference magnetic field generating unit to produce a reference magnetic field of known strength.

[0081] S105: Signal Acquisition and Parameter Calibration. During the application of the reference magnetic field, two calibration output signals are acquired simultaneously. First, the true magnetic field strength is calculated using the signal from the reference magnetic field detection unit. Then, based on the true magnetic field strength and the calibration output signal from the magnetic field sensing unit, its current real-time sensitivity calibration coefficient and zero-point offset calibration value are calculated.

[0082] S106: Storage and Application. The calculated calibration parameters are stored and used for software compensation of the subsequent real-time measurement output of the magnetic field sensing unit, thereby obtaining accurate and reliable final measurement values.

[0083] This invention features a novel structure, ingenious design, and simple and convenient operation. Through this design, it effectively achieves the effect of accurate early warning of early performance degradation of Hall sensors, realizing an upgrade from passive alarm to predictive maintenance, improving the accuracy of system decision-making, and reducing dependence on external calibration.

[0084] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A Hall sensor detection device, characterized in that, include: A magnetic field sensing unit is used to detect the strength of a first magnetic field around the object being measured and to generate a first magnetic field signal. A reference magnetic field detection unit is positioned to match the magnetic field sensing unit and is used to detect the second magnetic field strength in the area where the magnetic field sensing unit is located and generate a second magnetic field signal. A reference magnetic field generating unit is used to generate a reference magnetic field of known strength in the region where the magnetic field sensing unit is located; The signal processing and control unit is electrically connected to the magnetic field sensing unit, the reference magnetic field detection unit, and the reference magnetic field generating unit, respectively. The signal processing and control unit is configured as follows: Receive the first magnetic field signal and the second magnetic field signal; Based on the comparison results of the first magnetic field signal and the second magnetic field signal, the working state of the magnetic field sensing unit is determined; The reference magnetic field generating unit is controlled to operate, and during the application of the reference magnetic field, the parameters of the magnetic field sensing unit are calibrated based on the first magnetic field signal and the second magnetic field signal. The signal processing and control unit is configured to calibrate the parameters of the magnetic field sensing unit in the following manner: While controlling the reference magnetic field generating unit to generate a reference magnetic field of known intensity, the first calibration output signal of the magnetic field sensing unit and the second calibration output signal of the reference magnetic field detection unit are simultaneously acquired. Based on the second calibration output signal and the known sensitivity of the reference magnetic field detection unit, the true calibration magnetic field strength is calculated. Based on the actual calibration magnetic field strength and the first calibration output signal, the real-time sensitivity calibration coefficient and / or zero-point offset calibration value of the magnetic field sensing unit are calculated.

2. The Hall sensor detection device according to claim 1, characterized in that: The reference magnetic field generating unit is a micro coil or a soft magnetic material magnetization unit, which is configured to generate a stable or transient reference magnetic field of a preset intensity in the area where the magnetic field sensing unit is located in calibration mode.

3. The Hall sensor detection device according to claim 1, characterized in that: The signal processing and control unit is configured to determine the operating state of the magnetic field sensing unit in the following manner: In response to each signal sampling, the first magnetic field strength calculated based on the first magnetic field signal and the second magnetic field strength calculated based on the second magnetic field signal are compared; If the absolute value of the difference between the two exceeds the first preset threshold, it is determined that the magnetic field sensing unit has experienced performance degradation. If the absolute value of the difference between the two exceeds a second preset threshold greater than the first preset threshold, then the magnetic field sensing unit is determined to have suffered a serious failure.

4. The Hall sensor detection device according to claim 3, characterized in that: The signal processing and control unit is also configured to perform graded safety response actions when performance degradation or serious failure is determined to occur, including issuing a warning signal, degrading operation, or disconnecting the drive circuit.

5. The Hall sensor detection device according to claim 1, characterized in that: The signal processing and control unit is further configured to store the calculated real-time sensitivity calibration coefficient and / or zero-point offset calibration value in a non-volatile memory, and to use it to perform real-time compensation on the first magnetic field signal subsequently output by the magnetic field sensing unit.

6. The Hall sensor detection device according to claim 1, characterized in that: The triggering conditions for parameter calibration include at least one of the following: system power-on initialization, detection that the system is in a no-load idle state, temperature change exceeding a set value, and receiving an external calibration command.

7. A Hall sensor detection method, characterized in that, The method, applied to the Hall sensor detection device as described in any one of claims 1-6, comprises: The second magnetic field strength in the area where the magnetic field sensing unit is located is detected in real time by the reference magnetic field detection unit, and a second magnetic field signal is generated. The magnetic field sensing unit detects the strength of a first magnetic field around the object being tested and generates a first magnetic field signal. Based on the comparison results of the first magnetic field signal and the second magnetic field signal, the working state of the magnetic field sensing unit is determined; The reference magnetic field generating unit is controlled to generate a reference magnetic field of known strength; During the application of the reference magnetic field, the first calibration output signal of the magnetic field sensing unit and the second calibration output signal of the reference magnetic field detection unit are acquired simultaneously. Based on the second calibration output signal and the known sensitivity of the reference magnetic field detection unit, the true calibration magnetic field strength is calculated. Based on the actual calibration magnetic field strength and the first calibration output signal, the real-time sensitivity calibration coefficient and / or zero-point offset calibration value of the magnetic field sensing unit are calculated. The sensitivity of the magnetic field sensing unit is corrected using the real-time sensitivity calibration coefficient, and zero-point correction is performed using the zero-point offset calibration value.

8. The Hall sensor detection method according to claim 7, characterized in that: Determining the operating state of the magnetic field sensing unit includes: In response to each signal sampling, the first magnetic field strength calculated based on the first magnetic field signal and the second magnetic field strength calculated based on the second magnetic field signal are compared; If the absolute value of the difference between the two exceeds the first preset threshold, it is determined that the magnetic field sensing unit has experienced performance degradation. If the absolute value of the difference between the two exceeds a second preset threshold greater than the first preset threshold, then the magnetic field sensing unit is determined to have suffered a serious failure.

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