Hall Sensor Magnetic Field Alignment for Ferromagnetic Position Detection
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Solution Overview
Problem
Existing integrated magnetic field sensors with Hall sensors and permanent magnets have low sensitivity due to geometric alignment, resulting in minimal or no Hall voltage without external ferromagnetic influence, limiting their ability to detect changes in magnetic flux density effectively.
Innovation Solution
The integration of a semiconductor body and permanent magnet on a common metal carrier, with magnetic field lines aligned parallel to the main extension plane of the Hall sensor, increases sensitivity by generating a Hall voltage only when a ferromagnetic component alters the flux density, allowing for precise position determination of the ferromagnetic component through calibration and Hall voltage measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the Hall sensor is geometrically aligned to the permanent magnet, then the device complexity is reduced and manufacturing is simplified, but the sensitivity is reduced and Hall voltage is minimized without external ferromagnetic influence
Solution Approach 1:
Instead of aligning the Hall sensor to detect magnetic field lines directly from the permanent magnet (conventional approach), the patent inverts the approach by aligning the Hall sensor parallel to the magnetic field lines, deliberately creating a configuration where no Hall voltage is generated without external ferromagnetic influence. This inverted geometry makes the sensor specifically sensitive to changes caused by external ferromagnetic components.
Solution Approach 2:
The patent changes the geometric parameter of the Hall sensor alignment from perpendicular to magnetic field lines (conventional) to parallel alignment. This parameter change transforms the sensor's response characteristics, making it generate Hall voltage only when external ferromagnetic components alter the magnetic flux density, thereby optimizing sensitivity for specific measurement applications.
2Length of stationary object
If the distance between the Hall sensor and permanent magnet is reduced, then the magnetic flux density increases, but the sensitivity to external ferromagnetic components may be compromised without proper geometric alignment
Solution Approach 1:
The patent optimizes the distance parameter between the Hall sensor and permanent magnet to less than 10 mm (preferably less than 2 mm, most preferably less than 0.7 mm) and combines it with parallel geometric alignment. This parameter optimization ensures sufficient magnetic flux density while maintaining sensitivity to external ferromagnetic components through the specific alignment configuration.
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 configuration enhances the sensor's sensitivity and accuracy, enabling the detection of even slight changes in magnetic flux density and position of ferromagnetic components, with increased Hall voltage generation and improved detection accuracy.
Implementation Method 1
a Hall sensor (40) on the surface. The Hall sensor (40), which is preferably embodied as a Hall plate, has a main extension surface running parallel to the surface of the semiconductor body (30)
Data Source
Figure 1~3
AI summary
The integrated magnetic field sensor (10) has a semiconductor body (30) with an upper surface and a rear surface. A surface (55) of a magnet (50) is formed perpendicular to a main extension surface of Hall sensor (40). A central axis (M) runs parallel to the main extension plane of the Hall sensor. The central axis passes in a perpendicular manner through a standard (N) of the main extension surface. The standard stands in a centroid of the main extension surface. The field lines of the magnet run parallel to the main extension surface of the Hall sensor such that a Hall voltage is generated, when a part of the magnetic field lines is deflected by a ferromagnetic component (100) perpendicular to the main extension plane of the Hall sensor. An independent claim is included for a method for a determining a position of a ferromagnetic component.