ams.

com

White Paper
Smart hall sensors with built-in
stray field immunity as ideal
solution for position measurements
in harsh automotive environment

By Michael Pichler
White Paper
Smart Hall Sensors

Smart hall sensors with built-in stray field

immunity as ideal solution for position
measurements in harsh automotive environment
By Michael Pichler

Introduction
Hall effect magnetic sensor technology has been used to detect the presence or position of a magnetically polarized device for decades.
Since around 2010, sensor companies including ams AG have sought to increase the value of magnetic position sensors by integrating
the complete signal chain, from Hall sensor elements to signal conditioning, signal processing and communications interfaces, in a single
system-on-chip produced in a standard CMOS fabrication process.
The goal of this integration effort has been to produce magnetic position sensor systems which are:
- Smaller and lighter, so that they can be accommodated in space-constrained applications
- Competitively priced, benefiting from the at-scale production economies of CMOS chip processes
- Easier to implement in application designs, providing computed position coordinates via a range of standard interfaces supported by
most microcontrollers and microprocessors
- Equipped with valuable features, including monitoring, safety and diagnostics capabilities which help to provide for reliable operation

Magnetic sensor chip manufacturers have pursued various approaches to the integration of Hall effect technology, and their products
offer different trade-offs of cost against performance and capability.
In the automotive sector, the application of magnetic position sensors is subject to unique and extremely demanding requirements.
This white paper explains why general-purpose magnetic position sensors inadequately satisfy these requirements, and describes how
unique, and in some cases patent-protected, sensor technologies developed by ams provide the reliability, robustness and accuracy
required for operation in tomorrow’s passenger cars and commercial vehicles.

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1. The Hall magnetic effect: the dominant technology

in magnetic position sensing

1.1 Attributes of Hall effect magnetic sensors

The Hall effect, discovered by American physicist Edwin Hall in 1879, is the voltage difference which occurs across a current-carrying
conductor when a magnetic field is applied perpendicular to the current. The size of the voltage difference depends on the material from
which the conductor is made, the current flow, and the strength of the magnetic field. Mathematical models for the operation of the Hall
effect are well known and readily available for use in the development of magnetic detection switches and position sensors.
A Hall effect sensor will include one or more embedded magnetic elements. When an external magnetic field comes into proximity with
the sensor, it changes the polarity and strength of the embedded magnetic field. As the magnetic field changes, so does the voltage
difference across the sensor.
This enables the sensor to detect the presence of an external magnetic field – a useful function in simple magnetic switches which detect
the opening and closing of the lid of a laptop computer, for instance – this application requires a Hall effect sensor and a magnet on either
side of the laptop’s hinge.
Since the turn of the century, Hall effect sensor technology has evolved to enable extremely precise and accurate measurement of linear
and rotary position. A typical rotary position sensor, the AS5270 from ams, features maximum integral non-linearity of ±1.4°, and measures
rotary position in 12-bit resolution (that is, in increments of 0.09°).
A rotary position sensing application may be implemented with a simple assembly consisting of a fixed sensor board mounted perpendicular
to a rotating magnet mounted on-axis on the shaft of the rotor. This total assembly is small and light – an important attribute in mobile and
portable end products. The AS5270, for example, has a footprint of just 6mm x 6mm, and typically requires fewer than ten small external
components on the sensor board.
Magnetic position sensors are not only small and light – they also offer marked system cost advantages over alternative sensor technologies.
Device manufacturers have developed the capability to produce Hall effect magnetic sensors in standard complementary metal-oxide
semi-conductor (CMOS) fabrication processes. Since CMOS processes are supported by a large and well established ecosystem of tools,
materials and equipment suppliers, they allow semiconductor sensors to be manufactured economically in high volumes.

Fig. 1: Generic signal path of

ams magnetic position sensor.
(Image credit: ams)

1.2 Comparison with other position sensor technologies

The attributes of magnetic position sensors are in contrast to those of older position sensing technologies used in legacy designs for
applications such as motors.
Potentiometers use a contacting method for measuring rotary motion. A potentiometer consists of a resistive element, a sliding contact
(wiper) which moves along the element, electrical terminals at each end of the element, a mechanism such as a rotor which moves the
wiper from one end to the other, and a housing containing the element and wiper. As the wiper moves along the element, the resistance
of the element changes. By measuring this resistance change, the potentiometer can measure position.
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Because the potentiometer is a contacting technology, it is subject to mechanical wear and tear and performance may be disturbed
by shocks or vibration. In addition, contamination on the resistive element – dirt, dust, grease or moisture – can impair performance or
even cause premature failure. Expensive and cumbersome housings may be used to seal the potentiometer and prevent the ingress of
contamination.
Contactless magnetic sensing technology is immune to such contamination, so no such protection is required. As a result, magnetic sensor
systems tend to be smaller, more economical and more reliable than potentiometers, which are disfavoured in automotive applications
today.
Optical encoders measure position by sensing the pattern of light and dark as a codewheel with cut-out spaces rotates between an LED
light source and a photodiode light sensor. The succession of light pulses and darkness enable position to be accurately measured even
at high rotation speeds.
Since an optical encoder is a contactless technology, like a magnetic position sensor, it does not suffer from mechanical wear and tear.
But contamination can impair the performance of the emitter and light sensor, leading to reliability concerns in automotive use cases. In
addition, optical systems are bulky and require precise assembly with very low tolerances.
The resolver is a mature and familiar technology for use in rotary position sensing in automotive applications. It measures position
accurately at high rotation speeds. Resolvers, however, are large, heavy and expensive – attributes which have encouraged automotive
system designers to adopt magnetic sensor alternatives in a growing range of applications.
In consumer and many industrial applications, the Hall effect magnetic sensor was already a hugely popular device type. Basic magnetic
sensors used as switches, detectors and position indicators are widely used because of their long life, small size and low cost.
These commodity parts, however, have been found to be unsuitable for the special operating conditions that apply in the automotive
sector.

2. Where commodity, lowest-cost Hall technology fails:

the special requirements of the automotive sector

2.1 Growth in demand for magnetic sensors in automotive applications

Demand for compact, accurate position sensors is poised to grow substantially in automotive applications. The global automotive market
for magnetic sensors, worth just over $1bn in 2018, is forecast to grow to $1.6bn by 2026.
This growth is largely driven by electrification, not only of the traction system but also of auxiliary functions such as power steering and the
clutch. Electronic rather than mechanical or hydraulic actuation and control of functions such as steering and gearing produces improved
performance, higher reliability and reduced weight and size.
Automotive applications for Hall sensor technology in which these attributes are particularly important include:
- Motor position sensor in electric power steering
- Chassis position sensor
- Motor position sensor in dual-clutch transmission
- Traction motor position sensor in hybrid electric and fully electric vehicles
- Steering angle sensor
In these applications, the Hall effect magnetic sensor has become the dominant technology, strongly preferred to the alternatives
described in section 1.2 above.
- The lower weight of a Hall sensor solution supports car manufacturers’ efforts to reduce fuel consumption
- The smaller size increases mechanical design flexibility
- The lower cost at high volume of CMOS devices compared to alternative technologies such as the resolver aids automotive
manufacturers’ bill-of-materials cost management

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2.2 Special requirements for application of magnetic sensors in automotive designs

The appeal of Hall effect magnetic sensor technology to designers of important and safety-critical automotive functions, then, is strong.
But the automotive sector has special requirements for quality, reliability and safety which prohibit the use of the commodity and general-
purpose Hall effect sensors which are widely used in high volumes in consumer electronics.
- Quality: the automotive sector’s ultra-high requirements for repeatability, traceability and production quality are specified in
certifications such as PPAP and ISO/TS 16949 and in the AEC-Qxxx series of standards. These standards apply not only to the component
(chip) but to the complete sensor assembly.
- Reliability: devices used in critical automotive applications are specified to operate over a minimum lifetime of ten years, and over a
wider temperature range than is normal for consumer or industrial devices.
- Safety: the ISO 26262 functional safety standard which applies to electronics systems in vehicles has dramatically intensified car makers’
focus on safety design and safety performance of electronics systems, including the performance of position sensing systems based on
Hall effect devices.
In all three of these parameters, general-purpose Hall sensors expose automotive OEMs to a heightened risk of failure, or do not conform
to the automotive sector’s typical performance specifications. Car manufacturers’ experience of even some automotive-qualified magnetic
position sensors installed in production vehicles has exposed reliability problems and safety concerns.

2.3 The risks attributable to stray magnetic interference

The most important cause of reliability problems in automotive position sensors is external magnetic interference. A Hall effect sensor
operates by detecting and measuring changes in the magnetic field at the chip’s surface induced by the movement of a small, weak
magnet close to the sensor. In a benign operating environment free of external magnetic fields, the voltage signal generated by changes
in the chip’s magnetic field is wholly attributable to the movement of the paired magnet.
But a car is anything but a benign operating environment for a magnetic sensor. Components in the car such as motors, solenoids and
high-voltage cabling generate strong magnetic fields. If these components are close to the sensor, their ‘stray’ magnetism can interfere
with the magnetic field produced by the paired magnet, and thus distort the signal sensed at the sensor chip’s embedded Hall sensing
elements.
Such distortion can cause random measurement errors and impair the accuracy of the sensor’s position measurement outputs. In an
electric vehicle’s traction motor, for instance, this could lead to a severe reduction or total loss of motive power, or to uneven, jerky and
unpredictable rotation of the wheel.

2.4 Quality and safety concerns of automotive users of magnetic position sensors
The implementation of magnetic sensors in automotive motors has also put the spotlight on the repeatability of the assembly’s
construction in production units. All Hall effect position sensors measure position relative to a paired magnet. In a motor, for instance, the
paired magnet mounted on the shaft of the motor rotates relative to a static sensor IC.
Each sensor IC will have a specified tolerance of the variation in the air gap between the sensor and the magnet, and of misalignment
between the center point of the magnet and the center point of the sensor. Automotive manufacturers have faced production quality
problems arising from a mismatch between the assembly tolerance achievable in a production setting and the tolerance specified by the
sensor IC.
The use of magnetic position sensors has also come into question following the adoption of the ISO 26262 functional safety standard.
Compliance with ISO 26262 calls for a rigorous Failure Modes and Effects Analysis (FMEA) at the system level, and for safety counter-
measures to combat the risks associated with known failure modes.
In position measurement systems based on the use of a magnetic position sensor, this FMEA highlights the need for guaranteed detection
of faults in the sensor, and for built-in safety procedures to ensure continued operation or safe shutdown on detection of a fault.
Commodity magnetic position sensor products lack the diagnostic, monitoring and fail-safe features required to guarantee system
safety in the event of device failure. They are also not supported by ISO 26262-compliant development and production processes and
documentation.

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3. Smart Hall sensors: enhanced Hall effect sensor technology to meet

the requirements of the automotive sector

Above, ams has described the quality, reliability and safety design concerns which have emerged from the experience of using general-
purpose, commodity magnetic position sensors, even if these sensors have been modified to achieve AEC-Qxxx automotive qualification.
This paper will now describe a series of technical innovations implemented by ams in magnetic position sensors intended for use in
automotive applications such as the traction motors of electric and hybrid electric vehicles, electrical power steering systems, chassis
and suspension control systems, dual-clutch transmissions and steering systems. Together, these innovations have enabled ams to create
a new category of ‘Smart Hall sensors’ enhanced magnetic sensors which provide the reliability, quality and safety features needed to
support a lifetime of operation in challenging automotive conditions.

3.1 Differential sensing for stray magnetic interference immunity

ams is well known in the sensor community for inventing the first semiconductor-based technology to offer immunity against stray
magnetic interference of almost any amplitude.
The ams differential sensing technique is based on the use of two pairs of Hall sensor elements on each die; each element is equidistant
from the center of the die. To calculate rotary position or angle, the on-chip processor measures the difference between the magnetic
signals generated by the two pairs of Hall elements. Since any stray magnetic field can be assumed to have an equal effect on both pairs
of Hall elements, the differential measurement method automatically subtracts external interference.
ams automotive magnetic sensors are qualified for immunity against external magnetic fields equivalent to a conductor carrying 4,000A/m
according to the terms of the ISO 11452-8:2015 standard.

Fig. 2: No shielding required due to ams

differential measurement technology.
(Image credit: ams)

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3.2 Dual-die package technology for full redundancy

Patented ams technology enables the fabrication of dual-die sensor packages which provide full redundancy: in the event that one sensor
die fails, the redundant second die can instantly take over measurement operations. The innovation by ams is to place the redundant die
underneath the primary die, so that the footprint of the dual-die package is the same as that of a conventional single-die device. This
space-saving design simplifies the automotive manufacturer’s board layout while supporting use in ISO 26262-compliant systems which
have an ASIL C or ASIL D grading.

Fig. 3: ams Dual-Die Package. Fully

redundant sensor in one housing.
(Image credit: ams)

3.3 Advanced safety features for ISO 26262 compliance

In addition to patented dual-die package technology, ams intellectual property extends to various other features which support
compliance with functional safety standards. These features include:
- Automatic detection of a failed Hall sensor element
- Extended on-chip fault diagnostics, including detection of a missing or misaligned magnet
- Fail-safe features to provide for safe system operation in the event of sensor failure
- Automatic Gain Control (AGC) boost

3.4 Development processes compatible with functional safety

In evaluating position sensors for use in safety-critical automotive systems, many design teams will start by studying a product’s features
and specifications.
For ISO 26262 compliance, however, the sensor development and production processes also require careful specification. The special
requirements of functional safety are fully catered for by ams’s position sensor development. In particular, the ams development method
for position sensors is classified as a Safety Element out of Context (SEooC) process. In addition, ams provides ISO 26262-compliant
documentation for all automotive position sensors, including FMEA, safety manuals and safety audits.

3.5 Packaging and assembly innovations

The quality of an automotive position sensor system depends on two factors: the inherent quality of the position sensor module itself, and
the quality of its assembly in the application. In the assembly of a motor, the most important parameter is alignment with the shaft of the
motor: in general, magnetic position sensor systems are designed to be centered over the shaft. Misalignment can seriously impair the
accuracy of the sensor’s angle measurements.
Patented ams technology for motor alignment dramatically simplifies the process of calibrating an assembled unit on the production
line, helping automotive manufacturers to achieve high quality and repeatable results across an entire production run while minimizing
re-work.
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Innovation at ams also extends to the introduction of automotive position products in a System-in-Package (SiP) format incorporating
both the sensor and external components, eliminating the need for the customer to develop and manufacture its own position sensor
circuit board.

Fig. 4: ams System In Package.

Sensor die + passive components
is one package.
(Image credit: ams)

3.6 Performance innovations

The quality requirements of automotive systems impose tighter tolerances for the accuracy of measurement outputs than typical consumer
applications do. Put simply, automotive system designers demand a high level of confidence that all production units of a position sensor
will achieve in the application the accuracy that the datasheet claims it will offer.
The achievement of consistent quality across a population of production units is the goal of a number of patented ams technologies
implemented in its automotive position sensors. These include:
- DAEC™ technology (Dynamic Angle Error Compensation), which compensates for the effect of propagation delay in the sensor at high
rotation speeds, producing highly accurate compensated angle measurements at rotation speeds up to a maximum of 28,000rpm.
- Dynamic offset correction, which automatically corrects for the measurement offset inherent in all magnetic position sensors. This self-
calibrating technology eliminates the need for end-of-line calibration, and corrects for the influence of temperature drift over the lifetime
of the sensor.
- Automatic Gain Control (AGC), which widens the tolerance of the sensor system for variations in the assembly process. The AGC block in
ams position sensors automatically adjusts for differences in the air gap between the sensor and its paired magnet in the range 0-3mm.
It also adjusts for changes in sensor performance attributable to temperature swings and variations in the amplitude of noise, resulting
in highly stable measurement performance over time, temperature and operating conditions.

3.7 Automotive-specific features and resources

The magnetic position sensor range from ams has been extended to include features that are required by and unique to the automotive
sector, such as PSI5 and SENT interfaces.
ams also looks to support its automotive engineering customers through the provision of dedicated tools for evaluation and development
such as adapter boards, magnet holders, simulation software and LabView-based development software; by making available
demonstration systems for specific automotive applications, such as pedal angle sensing and electric power steering angle sensing; by
publishing magnet selection guidelines and magnet supplier recommendations alongside magnet analyses; and through a comprehensive
library of application notes, webinars and tutorial videos.

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4. Conclusion

Hall magnetic sensor technology has encountered resistance in the automotive industry after cost-driven attempts to deploy commodity
Hall sensor devices foundered. These devices’ operation was undermined by their susceptibility to stray magnetic interference and by the
difficulty of implementing them in system designs required to show compliance with the ISO 26262 functional safety standard.
It would be a mistake, however, to avoid the use of Hall technology just because some Hall effect devices have proved to be unsuitable.
Smart Hall sensor technology developed by ams maintains all the benefits of Hall effect semiconductors in position sensing applications:
Smart Hall sensor-based systems are small, light, robust and suffer no wear and tear or contamination.
But Smart Hall sensor enhancements implemented by ams mean that the devices offer the key features that automotive OEMs require,
including immunity to stray magnetic interference, ISO 26262 compliance, system-level quality, and high measurement accuracy and
linearity which are stable over time, temperature and operating conditions.

Because of the specific innovations implemented by ams in its range of magnetic position sensors, the Hall effect sensor can take its place
as a valued technology for any mission- and safety-critical application in the car, such as electric motor position sensing, pedal angle
sensing and steering angle sensing.

Biography
Michael Pichler is Senior System Engineer for contactless magnetic and inductive position sensors, with a focus on motor control and angle
sensing application within the automotive environment. He is also responsible for technical key account support regarding system design
and sensor integration.

For further information

ams AG Headquarters
Tobelbader Strasse 30
8141 Premstaetten · Austria
Phone +43 3136 500-0
sensors@ams.com
www.ams.com

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