Dual-Magnet Hall Sensor Layout for Flux-Concentrated Position Sensing
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Solution Overview
Problem
Conventional Hall effect sensor arrangements experience reduced magnetic flux due to magnetically-responsive materials, leading to diminished sensor performance and design limitations.
Innovation Solution
A configuration using multiple magnets with reversed polarities arranged side-by-side to create a more directed magnetic field, compensating for reduced flux and ensuring sufficient sensor functionality even in the presence of magnetically-responsive media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If magnetically-responsive materials are used in the sensor arrangement, then the structural integrity and mechanical properties are improved, but the magnetic flux at the Hall effect sensor is reduced
Solution Approach 1:
The patent divides the magnetic field generation into multiple independent magnets (first magnet and second magnet) with opposite polarities. This segmentation allows each magnet to be positioned independently to optimize flux distribution while maintaining structural integrity through the use of magnetically-responsive materials in the housing and shaft.
Solution Approach 2:
The patent applies different magnetic polarity orientations to different locations (first magnet with first polarity, second magnet with opposite polarity) to create a directed aggregate magnetic field. This local quality variation ensures that magnetic flux is concentrated toward the Hall effect sensor while magnetically-responsive materials provide structural support without excessive flux absorption.
2Device complexity
If a single magnet is used in the sensor arrangement, then the device complexity is reduced, but the magnetic flux concentration and sensor performance are insufficient
Solution Approach 1:
The patent segments the magnetic field generation into multiple magnets with specific polarity arrangements. This segmentation creates a more directed aggregate magnetic field that concentrates flux toward the Hall effect sensor, improving measurement precision while maintaining reasonable device complexity through systematic arrangement.
Solution Approach 2:
The patent uses asymmetric polarity arrangement where the first magnet and second magnet have opposite polarities oriented to direct magnetic flux toward the Hall effect sensor. This asymmetric configuration optimizes flux concentration and sensor performance while avoiding the complexity of fully symmetric multi-magnet arrangements.
3Quantity of substance
If magnets are positioned close to the Hall effect sensor to increase flux, then the magnetic flux concentration is improved, but the risk of magnetic flux shorting through magnetically-responsive materials increases
Solution Approach 1:
The patent positions multiple magnets with specific polarity orientations to create a directed aggregate magnetic field that concentrates flux toward the Hall effect sensor. This local quality control ensures flux is directed where needed while the distributed arrangement reduces the risk of flux shorting through magnetically-responsive materials compared to a single close-positioned magnet.
Solution Approach 2:
The patent acknowledges that magnetically-responsive materials can cause flux shorting but converts this potential harm into benefit by using these same materials in the housing and shaft to provide structural integrity while the multi-magnet arrangement directs flux through controlled paths that minimize unwanted shorting.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances magnetic flux concentration towards the Hall effect sensor, maintaining sensor performance and enabling precise position detection despite magnetically-responsive materials, and allowing for multiple sensors to differentiate positions accurately.
Implementation Method 1
A Hall effect sensor 12 that is spaced apart from the magnet 10 in a direction that is substantially perpendicular to the direction of the magnetic field of the magnet
Implementation Method 2
the plurality of magnets is arranged to produce an aggregate magnetic field having a flux concentration directed toward the Hall effect sensor
Data Source
AI summary
The present subject matter relates to devices, systems, and methods for identifying the position of a movable component. A position sensor system is provided in which a Hall effect sensor is coupled to a fixed housing, and a plurality of magnets is coupled to a movable component that is movable to a sensing position at which the plurality of magnets is proximal to the Hall effect sensor. In this configuration, the plurality of magnets is arranged to produce an aggregate magnetic field having a flux concentration directed toward the Hall effect sensor when the plurality of magnets is in the sensing position.