Hall Sensor Phase Shift for Rotational Speed Detection
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Solution Overview
Problem
Conventional motor speed sensor assemblies for detecting rotational direction and speed are difficult to produce and assemble due to their complex design and requirement for multiple Hall effect sensor modules.
Innovation Solution
A rotating direction and rotating speed sensing device that includes a tested unit with a toothed disk, a housing with a mounting recess for a single Hall effect sensor, and a circuit board, where the Hall effect sensor is positioned to detect the toothed disk and output signals with a phase shift between 45 degrees to 135 degrees, simplifying the assembly process and reducing the number of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple Hall effect sensor modules are used to detect rotational direction and speed, then the detection accuracy is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple Hall effect sensing elements (first, second, third, and fourth sensing elements) into a single integrated Hall effect sensor module. This merging approach maintains the detection accuracy that would require multiple separate modules while reducing the overall device complexity and simplifying the assembly process. The multiple sensing elements work together within one module to provide both rotational direction and speed detection capabilities.
2Reliability
If the housing is curved and the circuit board is tipped at an angle to position leads perpendicular to the circuit board, then the electrical connection reliability is improved, but the manufacturing and assembly difficulty increase
Solution Approach 1:
Instead of curving the housing and tipping the circuit board at angles to achieve perpendicular lead orientation, the patent inverts the approach by making the leads themselves adaptable to different orientations. The leads are designed to extend from the Hall effect sensor module and can be positioned to connect with the circuit board in a straightforward manner, eliminating the need for complex curved housing structures and angled circuit board mounting.
3Measurement precision
If two Hall effect sensor modules are mounted on the housing spaced apart by a first angle, then the rotational direction detection accuracy is improved, but the assembly complexity increases
Solution Approach 1:
The patent merges the functionality of two separate Hall effect sensor modules into a single module containing multiple Hall effect sensing elements arranged at appropriate angles. The first and second sensing elements are positioned to detect magnetic field changes corresponding to rotational direction, while the third and fourth elements detect rotational speed. This single integrated module eliminates the need to assemble two separate modules at specific angles, greatly simplifying the assembly process while maintaining detection accuracy.
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
The proposed sensing device effectively detects the rotating direction and speed of a motor using a single Hall effect sensor, simplifying the assembly process, reducing production complexity, and enhancing maintenance ease while maintaining accuracy.
Implementation Method 1
The Hall effect sensing elements detect the toothed disk and make the first pin and the second pin respectively output a first signal and a second signal when the toothed disk rotates
Data Source
AI summary
A rotating direction and rotating speed sensing device includes a tested unit, a housing, and a Hall effect sensor disposed in the housing. The tested unit includes an output shaft, and a toothed disk sleeved on and driven by the output shaft. The Hall effect sensor positionally corresponds to the toothed disk for detecting rotating direction and rotating speed, and includes three Hall effect sensing elements spaced apart along a first straight line, and a first pin and a second pin respectively outputting a first signal and a second signal when the toothed disk rotates. The first straight line cooperates with a tangential direction of the toothed disk to form an included angle that ranges in a predetermined angle range, such that a phase shift between the first signal and the second signal ranges from 45 degrees to 135 degrees when the toothed disk rotates.