A new generation of contactless magnetic position sensors

Masson Grald, Jerance Nikola, Frachon Didier, Dorge Thierry, Ronnat Yannick, Richard Arlot
Moving Magnet Technologies
1 rue Christiaan Huygens,
25000 Besanon, France

Keywords: Rotating magnetic field, Position Sensor.

Abstract: Magnetic position sensors have several
advantages which make them attractive for
automotive applications: they are contactless (there
is no mechanical wear-out), insensitive to dirt, low
cost and MMT has been a leader in the development
of solutions based on measurement of magnetic field
amplitude based on Hall effect.
In this paper, we will present a new generation of
position sensors. This new development is based on
the direction measurement of the magnetic field
generated by a diametrically magnetized magnet [1].
We will focus on through shaft 360 angular sensors
and linear sensors adapted to large displacements
[10200 mm]. In the following article, first the rotary
sensor principle is explained and then its derivative.
The basic design considerations are explained
through examples of automotive applications and
more particularly through examples of powertrain
transmission sensors.
1

Moreover on table 1 you can see some examples of

applications where sensors are required in a
transmission system.
One typical example is an electromechanical system
(upper centre in the table 1) which has recently been
launched on the market. This system integrates a
rotary sensor to monitor the position of the output
shaft of the shift by wire actuator.

Introduction

In usual transmission system (manual or automatic)

gears are changed by the mean of a cable which
interfaces between the shifter and the gear box. But
recently, new systems were introduced for
conventional manual or automatic transmissions
where the target is to replace the cable by an
electromechanical device in a gear box. (shift-by
wire).
Historically, the placement of shift levers in
automobiles has been limited primarily to the space
between the driver and passenger seats due to the
mechanical cable linkage necessary to connect the
lever to the vehicles gearbox. Shift-by-wire systems
were developed to eliminate the need for the
mechanical cable linkage by electronically controlling
the shifting in a vehicle.
These kinds of electromechanical systems require a
position sensor to monitor the position of the gear
shift lever or to provide an indication of the
transmission operation. One can find many different
types of sensors to fulfil this function, linear sensors,
rotary sensors, digital or analog directly attached to
the gear shift lever or integrated in an
electromechanical system in a gear box. One can
see in figure 1 an example of a manual gear box with
an actuator and clutch with sensor integrated.

Figure 1 : Example of a manual gear box and the

sensors location
Shift Position
sensor
integrated in
the Gearbox
actuator
Rotary or/and
Linear position
sensor

Shift lever
sensor
Rotary or Linear
position sensor

Clutch
Position
sensor
Linear position
sensor

The
Position
sensor
provides
two
inputs
for
position recognition
of the main selector
shaft
in
the
transmission.

The position sensor

detects up and
downshift requests
and are also used
for Selector Lever
position indication

Input
from
the
linear
sensor
providing
exact
clutch position.

Table 1 : Sensors examples located in a gearbox

Page 1/7

We will see through this paper that all these sensors

(rotary or linear ) can be replaced by the very new
MMT position sensor generation.
2

New generation of Field Direction Sensor

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Measurement of angular position using variation of

magnetic field amplitude induced by the
displacement of a moving magnet has been
intensively developed over the last fifteen years.
However, these solutions have limits in terms of
angular range and temperature influence. Recently,
new solutions based on the determination of the
angle of a rotating magnetic field have been
developed. They allow for a measurement of angles
up to 360 with limited temperature influence using
sine and cosine signals generated in a plane by a
rotating magnet. Typical set-up of these solutions is
to use a permanent magnet with a bipolar
magnetization placed at one end of a shaft and
facing
a
dedicated
Hall
ASIC.
However, several applications require a through
shaft, which prevents from using the basic principle
described hereabove. For this reason, MMT has
developed and patented innovative solutions for
through shaft magnetic position sensors using
measurement of the angle of a rotating magnetic
field, with a probe put next to the magnet. The
principle is also valid for linear sensors.
VOUT
Hall Switch

Input
Signal

Magnetic
Flux

Sensor
HALL

VOUT

does not follow the rotational angle of the shaft. In

this case, we should consider the magnetic field
components separately.

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Field Amplitude

)HUURPDJQHWLF
\RNHRSWLRQDO

Figure 3: Through shaft sensor overview

Theoritically, the solution for magnetic induction
outside a diametrically magnetized infinitely long
cylinder can be found in literature [4]. The following
analytical solution for radial and tangential field
component is obtained:
% UDG = % PD[ FRV
% WDQ = % PD[ VLQ ,
where % PD[ depends on radius as


.
U

Two sinusoidal signals with 90 phase shift are

obtained. For diametrically magnetized cylinders with
finite length, one must solve the field equations
numerically. The obtained solutions are, again, two
sine signals with 90 phase shift between them (4),
and their amplitude ratio depend on the magnet
dimensions.
% UDG = % UDG PD[ FRV ;
% WDQ = % WDQ PD[ VLQ

% UDG - radial induction

where:

% WDQ - tangential induction

Field Direction

%;

Figure 2 : Different principle of magnetic field

measurement
2.1

360through shaft Magnetic Field Angle

Position Sensor

2.1.1 Principle
In the proposed sensor solution [2] the ASIC for
magnetic field measurement is put next to a
diametrically magnetized magnet ring (Figure 3),
and, in this case, the angle of the magnetic field

induction (G)

%<

Ring magnet can be represented as a difference

between two disk magnets, so the solution for its
magnetic field will have the same form. An example
is given in figure 4, the results are obtained by
boundary element software [5].
350
300
250
200
150
100
50
0
-50 0
-100
-150
-200
-250
-300
-350

Brad
Btan

45

90

135

180

225

270

315

360

angle (deg)

Figure 4: Radial and tangential induction component

Measurement results
In most cases, practical measurement with a
diametrically magnetized ring magnet shows
significant non-linearity in the computed angle. The

Page 2/7

reason for this is found in the magnetizing process:

the magnetizing field is refracted on a magnet
surface, due to boundary conditions [4].

Figure 7: Angle computing block

Another possibility is to use axial and tangential field
components. It could be useful for some
embodiments needing the probe close to the
magnet. Magnetic flux sensor can be a multi-axis
Hall effect device that is commercially available from
Melexis [6] for instance.
Figure 5 : Magnetization coil
In Figure 6 this effect is shown both in simulated
result and in measured Brad and Btan. This effect
requires a specific know how in the magnetization
process and in the computation of the angle from
both components in order to get at the end a perfect
linearity.
measurement with bonded isotropic NdFeB

2.1.2. Practical realization

The 360 through shaft technology can be used in a
lot of automotive applications. At the beginning it
was designed for the steering angle measurement.
Indeed the steering angle sensor must deliver an
absolute position signal over 360, must be through
shaft, and requires a very good accuracy. A typical
design for this application is shown in the figure 8
and the measurement results of this sensor can also
be seen in this figure 8.

4,5
4
voltage (V)

3,5
3
2,5
2
1,5
1

Vrad

0,5

Vtan

0
0

90

180
angle ()

270

360

real magnetization =1.2*0

400
300

indcution (G)

200
100
0
-100

90

180

270

360

-200
-300

Brad

Figure 8: overview and measured non-linearity for

Steering Angle sensor @ several temperature

Btan

-400
angle (deg)

Figure 6: Real magnetization: measurement versus

simulation
In order to compute the angle of rotation, two
different gains are applied to signal components,
before the angle computation. Then it is possible to
obtain the rotational angle by computing the arc
tangent. Angle computing block is illustrated in figure
7, G1 being in general case different from G2.

The Non Linearity obtained is about NL=+/-0.5% (of

360 NL=+/-1.8) over the complete range of
temperature [-40C 125C].
With this sensor, we have tested the influence of
some geometric defaults that can occur during the
life of the sensor. By design, this new generation of
sensor is not sensitive to radial and axial shift since
we measure only the direction of the field, not the
amplitude of the field. To check this insensitivity to
geometric defaults two kinds of geometrical faults

Page 3/7

were tested: radial and axial shift. The measurement

results of both mechanical shifts for a magnet OD =
30 mm, ID = 26 mm, h = 5 mm is being dispalyed in
the folowing Figure 9.
5
Vout

Radial shift
Output Voltage (V)

NLin % dr= -0.4 mm

dr

4,5

0,8

0,6

3,5

0,4

0,2

NL in % dr=0 mm

2,5

-0,2

1,5

-0,4

-0,6

0,5

-0,8

0
-300

-250

-200

-150

-100

-50

50

100

-1
150

Figure 11: Measured non-linearity for small size

sensor

stroke (deg)

tension (V )

dz

4,5

0,8

0,6

3,5

0,4

0,2

2,5

-0,2

1,5

-0,4

-0,6

0,5

-0,8

0
-300

-250

-200

-150

-100

-50

50

100

NL (% )

Vout
NL1 dz=0
NL2 dz=0.7
NL3 dz=-0.6

Axial shift

-1
150

angle (deg)

Figure 9: Geometrical defaults - measurement

results
We notice that the sensor can handle very large
tolerance during its life without any deterioration of
the accuracy.
Of course one can use this sensor in different
embodiments and for different applications. For
example a miniature prototype has been made
(Figure 10), to potentially replace small size
potentiometers in some applications. Magnet
dimensions are: OD = 7 mm, ID = 5.5 mm, h = 3
mm. The non linearity of the computed angle is
presented in the figure 11.

A 0.33% non-linearity on 359.5 stroke is obtained.

Thus, even small potentiometers can be replaced by
this type of sensor.
2.2. Magnetic Field Linear Position Sensor
2.2.1. Principle
The evergrowing need for an improved sensor that
displays minimal deviations due to changes in
temperature and that can be adapted for use over a
wide range of measurement angles is also valid for
the measurement of linear displacement. Therefore
MMT has tried and succeeded to extend the
principle of the 360 through shaft technology to the
measurement of distance. The idea is very simple
and by consequence very smart. For the 360
sensor the magnet is a complete ring, diametrically
magnetized to get rotating magnetic field vector. The
original idea was to magnetize diametrically a
flexible magnet wrapped around a ring and then
unroll it for use in a linear sensor configuration. This
principle is illustrated in Figure 12.

Figure 12 : process to get a linear position sensor

Figure 10 Overview and section view of a miniature

sensor

From this process, we end up with a flat magnet and

a rotating magnetic field with linear displacement
illustrated Figure 13.

Page 4/7

results are given in the figure 15. The non linearity is

equal to +/- 0.26% corresponding to +/- 0.0468mm.

0 0DJQHWL]DWLRQYHFWRU

Figure 13 : Rotation of the magnetic field with

displacement
Referring to Figure 13, a linear non contacting
position sensor is shown. This Sensor is adapted for
use in monitoring the linear position of an attached
object that moves such as shaft. A shaft can be
connected to any moving object such as an EGR
valve, transmission gear... The linear position sensor
includes a magnet and a magnetic flux sensor. The
magnetic field generated varies sinusoidally with
displacement and can be detected by a flux sensor
to sense the position of an object.
The original idea came from the use of a flexible
magnet but it might lead to some industrialisation
issues, since a flexible magnet is not easy to handle
in a production process. Therefore MMT has
developed some specific fixtures to avail
magnetization of classical rigid bonded magnets
(NdFeB, Ferrite). This specific tooling allows getting
a perfect sinusoidally variation of the magnetic field
with displacement.
2.2.2. Practical realization
A linear sensor can be used to detect the position of
the shifter (P-R-N-D for an automatic car) or to
monitor the position of the clutch, the position of an
EGR valve, can be used as pedal sensor etc. In this
kind of applications the displacement of the object to
monitor is about 15-20 mm. Thats the reason why
we have chosen to show an example of a 18mm
linear sensor. But there are no constraints to use this
kind of sensor for a very large stroke (>100mm), the
principle and the realization do not change.
In the figure 14 one can see the embodiment of the
sensors and position of the ASICS. The
displacement of the magnet is along the X axis.
y

Figure 15: Output signal and NL measurement

results
2.3. Magnetic Field short angle Position Sensor
2.3.1 Principle

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In other possible embodiments, only a small part of a
ring magnet could be used to measure an angle
inferior to 360 degrees of rotation of an attached
object. A lot of automotive application does not
require measuring the complete rotation of an object
but only 50 to 90 of rotation (gear shift lever, Fuel
sensor, EGR valve etc). In this specific case it can
be cost effective to save magnet volume and so to
use only a tile magnet instead of a complete ring.
From what have been seen up to now, there are two
solutions to realize such sensor (table 2):
-To use a tile magnet diametrically magnetized and
have a partial magnetic field rotation and
-to use a tile magnet sinusoidally magnetized to get
a complete magnetic field rotation

Figure 14: Linear sensor example

One can see that the linear sensor leads to the same
accuracy as the rotary sensor. The measurement

Page 5/7

A tile magnet
diametrically magnetized

A tile magnet with a

complete magnetic field
rotation

Diametrically magnetized

Sinusoidally magnetized

400

400

300

300

200

200

Figure 18 : Sensor overview and radial and

tangential induction component

Bradial

0
-30

-20

-10

10

20

30

-100
-200
-300
-400
Stroke in

Induction in Gauus

Induction in Gauss

Btangential

100

100
0
-30

-20

-10

10

20

30

-100
-200

Bradial

the radial and tangential components of the

magnetic field generated by this magnetization in the
same figure.

-300

Btangential

-400
Stroke in

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VWURNH

From these 2 components and some optimized

parameters in the computation of the ATAN, it leads
to an output signal with a very good linearity. One
can see the output voltage (in V) obtained after
computing the ATAN and the non linearity in % (of
80) over the [-40C 150C] range of temperature in
the Figures 19 and 20.

Both solutions are valid, on one hand the first

solution is very simple to magnetize but a little bit
more sensitive to some defaults and on the other
hand the second solution is more accurate in term of
angle Resolution and insensitive but requires a
specific magnetization tooling to be able to use a
classical rigid magnet.
2.3.2 Practical realization
The sensors used to monitor the position of the gear
shift lever or to provide an indication of the
transmission operation are usually rotary position
sensor for strokes from 40 to 90. That means the
sensors presented in this section are well indicated.
One can see an example of an integrated sensors
to provide the position of the shift lever.
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5RWDU\SRVLWLRQ
VHQVRU
Figure 17: Rotary sensors integrated in a shift lever

Figure 19 : Output signal in V

Figure 20 :
Non Linearity in % over the temperature range
The blue curve corresponds to the non linearity (NL)
at -40C, the green one to the NL at 25C and the
red one corresponds to the NL at 150C. One can
see we got an accuracy of +/- 0.24 over the
complete
temperature
range
without
any
deterioration of the non Linearity.
Sinusoidally magnetized
In this configuration, we have a 80 tile magnet
magnetized sinusoidally and one can see the radial
and tangential components of the magnetic field
generated by this magnetization in the figure 21.

As indicated previously, we have two solutions for

magnetizing a tile magnet as a short stroke position
sensor. Both solutions diametrical and sinusoidal are
presented through measurement results.
Diametrically magnetized
In this configuration, we have a 100 tile magnet
(figure 18) magnetized diametrically. One can see

Figure 21 : overview and radial and tangential

induction component - measurement results

Page 6/7

In this case one can see almost a complete rotation

of the magnetic field and a quasi perfect SIN and
COS shape signals. It leads to a very good linearity
as it is shown in the figures 22 and 23.

Figure 22 : Output signal in V

Figure 23 : Non linearity in % at 25C

sous priorit franaise FR N05/11567 en date du

15/11/2005
3.
Capteur
de
position

direction
daimantation variable et procd de ralisation ,
demande PCT N PCT/FR/2007/000382 en date du
2/03/2007 sous priorit franaise FR N06/01877 en
date du 2/03/2006
4. E.P. Furlani Permanent magnet and
electromechanical devices, Academic Press, 2001
5. AMPERES, Integrated engineering software,
www.integratedsoft.com
6. MLX90316 datasheet, Melexis, www.melexis.com
Glossary
ASIC: Application-Specific Integrated Circuit

3. Conclusion
A new generation of low cost magnetic sensors is
proposed. Its performances are evaluated through
simulation and measurement results. Several
prototypes for different automotive applications are
realized. Through the examples presented, one can
see that the new generation of sensor can fit
automotive applications having medium to large
angular strokes (from several dozens up to 360
degrees and from a few to 200 millimeters), such as
steering, fuel level, pedal, air control valves sensors,
Gear & Shift travel sensor for Automated Manual
Transmission, sensor module for gear and shift
measurement, linear position measurement for
clutch master cylinder etc..
Moreover a good overall sensor performance
(typically 0.3-0.4 % non-linearity on any stroke) is
achieved and presents a lot of advantages:
-Simple and low cost structure (1 magnet / 1 ASIC)
-Possible redundancy in a single ASIC
-Highly scalable design (SMD sensor to steering
column)
-Up to 360solution
-No magnetic hysteresis
-Low sensitivity to geometrical tolerances
-Reduced sensitivity to temperature effects (no need
for temperature compensation)
-Possibility to use existing ASICs and various
measuring principles
-Other patented variants adapted to large linear
strokes or short angular strokes
Literature
1.
V. Hiligsmann - 360 Degree Rotary Position
Sensing with Novel Hall Effect Sensors, Sensors,
March 2006
2.
Capteur rotatif 360 notamment pour
colonne de direction automobile , demande PCT
N PCT/FR2006/002526 en date du 15/11/2006

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