Monolithic Hall Sensor Redundancy for Fault-Tolerant Rotation Angle
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Solution Overview
Problem
Existing integrated rotation-angle sensor units in the automotive field lack fault-tolerance, simplicity, and cost-effectiveness for accurate rotation angle determination, particularly in safety-critical applications like steering wheel angle measurement.
Innovation Solution
An integrated rotation-angle sensor unit with a semiconductor layer housing redundant monolithically formed Hall sensor systems and a control unit, featuring Hall sensors arranged in concentric circles to enhance resolution and compensate for static interfering fields, along with magnetoresistive sensors for improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single Hall sensor system is used for rotation angle determination, then the device complexity is reduced, but the reliability is insufficient for safety-critical applications
Solution Approach 1:
The sensor system is segmented into multiple independent Hall sensor systems (at least two) that are spatially separated and functionally independent. Each sensor system can operate autonomously to determine rotation angle, providing redundancy for fault-tolerant operation in safety-critical applications.
Solution Approach 2:
The patent implements redundant sensor systems in advance to cushion against potential failures. By having multiple independent measurement paths available before any failure occurs, the system can continue operating safely even if one sensor system fails, which is essential for safety-related areas.
2Measurement precision
If Hall sensors are arranged closely together to reduce device size, then the volume is reduced, but the measurement precision deteriorates due to interference
Solution Approach 1:
The patent applies local quality by arranging Hall sensors at specific positions on concentric circles with optimized angular separations (e.g., 120 degrees apart). This local optimization of sensor positions maximizes measurement precision for rotation angle determination while maintaining a compact overall sensor unit volume.
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 solution provides high-resolution, fault-tolerant, and cost-effective rotation angle determination, capable of compensating for static interference, such as the Earth's magnetic field, ensuring reliability in safety-critical applications.
Implementation Method 1
the position of a shaft is determined from the measurement of the magnetic flux by means of magnetic field sensors, for example
Implementation Method 2
magnetoresistive sensors for improved accuracy
Data Source
AI summary
An integrated rotation-angle sensor unit in a measuring system for rotation angle determination, with a shaft that is rotatable about an axis of rotation with a transmitter, The sensor unit has a semiconductor layer with a top surface that can be arranged perpendicular to the axis of rotation and has a bottom surface, and two monolithic Hall sensor systems are implemented in the semiconductor layer. Each Hall sensor system has at least a first Hall sensor, a second Hall sensor, and a third Hall sensor, and the three Hall sensors of the first Hall sensor system are arranged on a first circle that is parallel to the top surface of the semiconductor layer and can be arranged concentrically around the axis of rotation.