Hall Sensor Device Bridge Pin Configuration
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Solution Overview
Problem
The high manufacturing cost and low efficiency of Hall sensor devices arise from the need for multiple sensors with different pin configurations to meet varied customer requirements, leading to increased mold variations and interface design complexities.
Innovation Solution
A Hall sensor device system comprising two sensor chips, a directional and a non-directional Hall speed sensor chip, encapsulated in a shared shell with a bridge that connects the pins to match different customer interface requirements, allowing the same mold to produce sensors with three output pins for simultaneous rotating speed and direction detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple different sensor devices are used to achieve different functions, then different customer interface requirements can be met, but the manufacturing cost increases and the structure becomes less compact
Solution Approach 1:
The patent applies universality by designing a single sensor device that can serve multiple customer interface requirements. The device contains two Hall sensor chips (directional and non-directional) that can be configured through different bridge connection modes to provide different pin assignments, allowing one device to replace multiple specialized devices and reduce manufacturing costs.
Solution Approach 2:
The patent applies dynamics through the removable clamping element that can be positioned in different locations to change the connection mode. This dynamic reconfiguration allows the same physical device to adapt to different customer requirements by simply moving the clamping element, rather than requiring different fixed designs for each interface type.
2Adaptability or versatility
If multiple different sensor devices are used to achieve different functions, then different customer interface requirements can be met, but the structure becomes less compact
Solution Approach 1:
The patent merges two separate sensor functions (directional Hall sensor and non-directional Hall sensor) into a single device housing. Both sensor chips are integrated within the same shell with shared power supply and signal terminals, creating a compact unified structure that provides multiple interface configurations without requiring separate devices.
Solution Approach 2:
The unified sensor device structure can provide different interface configurations (first customer interface with signal pin assigned to first terminal, second customer interface with signal pin assigned to second terminal) through the removable clamping element, making the structure versatile yet compact rather than requiring multiple separate devices.
3Adaptability or versatility
If different moulds are adopted for different customer requirements, then specific pin configurations can be achieved, but the manufacturing efficiency decreases
Solution Approach 1:
The patent uses a dynamic removable clamping element that can be repositioned within the same mold to create different pin configurations. This allows a single mold to produce devices with different interface assignments by simply relocating the clamping element, eliminating the need for multiple specialized molds and improving manufacturing efficiency.
Solution Approach 2:
A universal mold design is implemented that can accommodate different clamping element positions to produce various pin configurations (first customer interface and second customer interface) from the same mold, making the manufacturing process versatile and efficient rather than requiring separate molds for each configuration.
4Adaptability or versatility
If different sensor interfaces are designed for different customers, then specific requirements can be met, but the manufacturing cost increases
Solution Approach 1:
The interface customization is achieved dynamically through the removable clamping element that can be positioned at different locations to create different signal pin assignments. This allows the same base device to be customized for different customers without requiring different manufacturing processes or additional costs.
Solution Approach 2:
A universal device design with customizable interface is provided, where the same hardware platform can be configured for different customer requirements through the removable clamping element. This universality reduces manufacturing costs by eliminating the need to produce entirely different devices for each customer interface specification.
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
This solution reduces manufacturing costs and improves efficiency by enabling the production of two types of sensors with different pin configurations using the same mold, facilitating quality control and meeting diverse customer needs while detecting rotating speed and direction simultaneously.
Implementation Method 1
a first Hall sensor chip and a second Hall sensor chip, one sensor chip being a directional Hall speed sensor chip and the other sensor chip being a non-directional Hall speed sensor chip
Implementation Method 2
a first Hall sensor chip and a second Hall sensor chip, one sensor chip being a directional Hall speed sensor chip and the other sensor chip being a non-directional Hall speed sensor chip
Data Source
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Figure 5
AI summary
The present invention refers to a Hall sensor device and a manufacturing method thereof. The Hall sensor device includes: two sensor chips each including two pins; a shell, in which four conductive terminals electrically connected with four pins respectively are arranged; three output pins electrically connected to three of the conductive terminals respectively; and a bridge suitable for electrically connecting the rest conductive terminal with the congeneric conductive terminal in the three conductive terminals. The manufacturing method includes: integrally molding the shell and four output pins electrically connected with the four conductive terminals respectively, and cutting off the output pin electrically connected with said rest conductive terminal and providing the bridge. By adopting the present invention, the manufacturing cost of the sensor device is reduced and the production efficiency is improved. Two configurations can be manufactured: one in which the two power supply pins are connected with each other, the other in which the two signal pins are connected with each other.