Sensors and Actuators A 106 (2003) 149154

Contactless position sensor using magnetic saturation

Bertrand Legrand a,b, , Yves Dordet a , Jean-Yves Voyant b , Jean-Paul Yonnet b
b

Siemens VDO Automotive S.A.S., 1 Avenue Paul Ourliac, 31036 Toulouse, France Laboratoire dElectrotechnique de Grenoble, ENSIEG, UMR INPG-UJF/CNRS 5529, 38402 Saint-Martin-dHres, France

Abstract This paper describes different structures for the realization of a contactless position sensor when restricting to a magnet as the target and an inductance as the sensing element. The principle of measurement is the local saturation of an inductance core by a magnet. A sensor model is explained using Maxwell equations on the magnetic circuit. Some response curves are also presented in order to validate the model. The experimental results obtained on a prototype of linear position sensor are given. 2003 Elsevier B.V. All rights reserved.
Keywords: Position sensor; Permanent magnet; Impedance measurements

1. Introduction Modern vehicles need numerous sensors in order to control actuators enhancing motor performances, safety and passengers comfort [1]. This paper describes magnetic sensors for position detection. The principle of measurement is the local saturation of an inductance core by a magnet [2]. It is presented in the rst part of the paper by using a model based on a reluctance network. Then the effect of eddy-currents will be explained and explicitly calculated. Finally, comparisons are made with nite-elements simulations and measurements on prototypes.

through the air-gap between the two branches. The operative air-gap is delimited on the left side by the core and on the right side by the saturated area which depends on the magnet position. The theoretical inductance of the coil is then calculated with the reluctance of the complete ux path dened in the Fig. 2. When neglecting eddy-currents, leakage ux and using a high permeability magnetic material, the reluctance R of the circuit is restrained to the operative air-gap zone (length , thickness g, width w) [4]. The inductance is clearly proportional to the magnet position . L= 0 N 2 w = 0 N 2 R g (1)

2. Sensor principle The magnetic structure of the sensor is presented in Fig. 1; it contains a U-shaped magnetic circuit, a concentrated coil is wounded around the core linking the upper and the bottom branches on their left extremities. Both coil and magnetic circuits create an inductance which is measured by an electronic device [3]. A magnet (considered as the target) moves along the trajectory T above the magnetic circuit and saturates part of it. Consequently, the inductance of the coil is modied depending on the magnet position. The coil is supplied with an alternate current (frequency f). The magnetic ux created by the coil circulates in the magnetic circuit as presented in Fig. 2. The ux path goes
Corresponding author. E-mail address: bertrand.legrand@leg.ensieg.inpg.fr (B. Legrand).

In order to reduce non-linearities, a differential structure (length l, shown in Fig. 3) can be use, and the response signal of the sensor is then directly proportional to the difference of the two inductances of the two coils (L1 and L2 ). w Vout = k(L1 L2 ) = 0 N 2 (2 ) (2) g 3. Sensor model and eld calculation For a quick response and noise rejection, the sensor is operated at relatively high frequency (510 kHz) when compared to classical 5060 Hz. The effect of eddy-currents is then of high inuence on the instantaneous eld distribution [5] and sensor linearity. Each sensor has to be adapted to its precise application depending on the required stroke, linearity and time response.

0924-4247/$ see front matter 2003 Elsevier B.V. All rights reserved. doi:10.1016/S0924-4247(03)00154-7

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Fig. 1. Basic principle of the sensor.

and justication of our analytical hypothesis. Fig. 4 shows the magnitude and orientation of the ux distribution at different particular time of the excitation current wave. These results are calculated using the magneto-dynamic calculation module which takes into account eddy-currents. On this gure, it is straight-forward that ux in branches behave like a progressive wave which propagates along the length of the branch while the magnitude of the wave is progressively decreasing (phase is also progressively shifting along the branch). It must be pointed out that the wave propagates mostly on the internal surfaces of branches. This is due to the particular place of ux source and return path which both are situated on the same surface of branches (i.e. bottom surface of the upper branch, and vice versa). Flux2D software reinforce this asymmetrical phenomenon in the branch because the case study is assumed innitely long in the z-axis direction. For easier calculations, we will seek for an analytical expression of the ux in the branches, taking account into eddy-currents, but in one-side of the branches. This calculation hypothesis gives results which are close either to numerical Flux2D determinations but also to experimental measurements. Calculations are performed using the classic Maxwells equations set (3) applied to a ferromagnetic material (physical characteristics given in Eq. (4)). Maxwells equations: Rot(E) = div(B) = 0 J = Rot(H) div(J) = Material equations: B = 0 fer H J = E =0 Material properties of the branches are considered linear in the active length of the sensor and elds are neglected in zones saturated by the magnet. Electromagnetic values are supposed homogeneous along the z-axis, neglecting end-effects on the sensor width. The one-side ux in the branches is nevertheless an assumption, as said before. The ux is considered purely longitudinal along x-axis in the branch. Currents J are therefore exclusively oriented on z-axis (reality is of course more complicated). Combining equation sets (3) and (4) with the notation in (5) gives the classic diffusion equation and solution form given in (6) and (8). 0 Hx (x, y) H = (5) , J = 0 0 0 jz (x, y) (4) dB dt (3)

Fig. 2. Main ux path in the sensor.

Each sensor will be a compromise between branch thickness, level of induction in the core and branches, level of voltage signals, working frequency, materials (ferrite, permalloy, etc. [6]), numbers of coils turns, sensor width, air-gap thickness, etc. The adaptation of the sensor to a particular application would therefore be arduous without precise knowledge of eddy-currents distribution in branches. On one hand, the core eddy-currents do not act on the sensor linearity, but act only on the level of signal, and will be neglected in the following calculations. On the other hand, eddy-currents in branches have to be calculated. We will use numerical modelisation results obtained with nite element software (Flux2D) for a quick introduction

Fig. 3. Differential structure.

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Fig. 4. Instantaneous ux vectors at different phase-times and high frequency excitation (skin depth of approximately 0.1 mm).

jHx =

Hx y

(6)

Skin depth is dened by the Eq. (7) and then the magnetic eld in the branches is given in Eq. (8). = 2 0 fer
((1+j)/)y

ux conservation and Amperes theorem on a loop (L) which follows the surface of the branch (Fig. 5), we found the nal expression for the ux in the air-gap: Hair (x, t) = K= 1+j fer g NI g + (gw/c Sc K) e
Kx+jt

uy

(9) (10)

(7) + C2 (x)e
((1+j)/)y

Hx = C1 (x)e

(8)

Field Hx is symmetrical in its general form. In our case, we have assumed that term C2 (x) can be neglected in order to reproduce a ux on only one-side of the branch. Using

The attenuation of ux along branch is then well described and roles of pulsation , skin depth , core surface Sc , relative permeability fer , conductivity and air-gap length are taken into account. This result is correct as long

Fig. 5. Amperes theorem and ux loop (L).

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Fig. 6. Magnetic eld in the air-gap (Model results) at phase: 45, 90, 135 and 180 .

as magnetic saturation is not reached in the skin depth of branches where induction is concentrated. Real part of root square of K is the attenuation length constant of the ux wave along x-axis. This length is much greater than the skin depth allowing sensor measurements on many centimeters.

The analytical expression of ux in the air-gap gives time or phase dependent numerical results shown in Fig. 6. These analytical results may be compared to Flux2D results drawn in Fig. 7. We can notice that phase/time-variations and attenuation are well reproduced by the analytical model.

Fig. 7. Magnetic eld in the air-gap (Flux2D results) at phase: 45, 90, 135 and 180 .

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Fig. 8. Inductance variation for one coil.

Fig. 9. Inductance variations for two coils of a differential sensor.

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Fig. 10. Difference of the inductances for a differential sensor.

4. Experimental results We have built a set of prototypes and made several measurements. The measured inductance L against position is shown on Fig. 8 for a single magnet. The exponential form of this curve is due to eddy-currents which counteract the ux distribution along the branches. This non-linearity is well suppressed using a differential structure as shown in Fig. 3. Fig. 9 shows the variation of the two inductances for a sensor in a differential mode. And in this case Fig. 10 shows an approximately linear output. We have obtained a stroke of 120 mm with a 200 mm sensor length. The linearity and stroke is enhanced when decreasing frequency but response time of the sensor is then increased.

magnets to create a local saturation of the ux path in an inductance coil. The value of the inductance depends on the position of the magnet. A complete modelisation of the sensor was explained, including eddy-current effects at high frequencies. This model ts well the experimental results. References
[1] D. Holt, Sensors and Automobile, vol. 106 (9), Automotive Engineering International, September 1998. [2] G. Asch, et al., Les capteurs en instrumentation industrielle, Dunod, Paris, 1998, pp. 319394. [3] R. Palls-Areny, J.G. Webster, Sensors and Signal Conditioning, Wiley, New York, 2001, pp. 277327. [4] H.C. Roters, Electromagnetic Devices, Chapman & Hall, London, 1947, pp. 116139. [5] R.L. Stoll, The Analysis of Eddy Currents, Clarendon Press, Oxford, 1974, pp. 2833, 5762. [6] Vacuumschmelze GmbH, Soft Magnetic Materials, Heyden, London, 1979, p. 264.

5. Conclusion An innovative type of sensor based on the saturation of a magnetic circuit has been presented. This sensor used