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A Novel Absolute Magnetic Rotary Sensor
A Novel Absolute Magnetic Rotary Sensor
A Novel Absolute Magnetic Rotary Sensor
fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TIE.2014.2387794, IEEE Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS
Abstract—To measure angular position of motors, robot joints, resolver-to-digital conversion method [ 7 ] to improve
etc, an absolute magnetic rotary position sensor is developed, performance of the resolver. In [8], a linear inductosyn sensor
which possesses small-size, light, robust, and easy-to-integrate with one excitation coil and two sensing coils had been
properties. The sensor consists of two inductors, a code disc, and a
developed. All these magnetic sensor have many advantages
signal processing part. Both of the two inductors are embedded
with a big planar spiral copper coil and four smaller ones by such as robustness and tolerance of dirt, oil, vibration and
employing MEMS technology, and there are two circles of regular low-noise effects [9,10,11]. However, the drawbacks of heavy
copper sheets listing on the surface of the code disc. Besides, weight and large volume are limitations to the sensors.
mathematical analysises of the inductor structure, the In the other type, the permanent magnet is commonly used to
relationships of position and dimension among the coils and the generate excitation signals and the magnetic encoder is one
copper sheet are addressed. Finite element simulation results
typical delegate. Based on the arrangement forms, the magnetic
demonstrate that one group of the optimal sine and cosine signals
can be generated by each inductor. Then, the absolute position encoder can be divided into two types. In [12], the spin valve
measurement method is validated by mathematical method. At used to generate signals was listed on the axial direction of the
last, experiments are performed on the high-speed and the permanent magnet. In this form, the sensor cannot be used in
low-speed testing platforms to assess effectiveness and accuracy of the hollow devices. In the other form, the sensing elements are
the sensor. on the radial direction of the magnetic ring. To the encoders of
this form, Z signal used to determine absolute zero point
Index Terms—Absolute magnetic rotary sensor, angular sensor,
electromagnetic sensor, magnetic encoder, resolver, sine-cosine
generates only once per circle. Therefore, they are usually
sensor. relative position sensors. To measure absolute angular position,
[13] developed a multi-pole magnetic rotary encoder. However,
I. INTRODUCTION the encoders are difficult to be magnetized [14]. Besides, as the
sine and cosine analog signals have to be transformed to digital
A bsolute angular position measurement is important in
automotive industry such as motor and robot arm control
[1,2]. The magnetic sensors, one type of the most frequently
pulse signals, the advantages of sinusoidal signals such as
simple, accurate and reliable to represent angular position are
lost [15]. What’s worse, the encoders require additional signal
used sensors in servo drive systems [3], have been developed
interpolation process both in hardware and software [16, 17]
by many different researchers and companies [4]. According to
and various dedicated converter schemes were designed
the excitation signal-generating mode - the electromagnetic
[18,19]. To make up these disadvantages of the encoders, some
induction or the Hall effect, the magnetic sensors are divided
other sensors were developed. Seung-Ho Jeong etc. [14] had
into two types. 1
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II. WORKING PRINCIPLE ANALYSIS OF THE SENSOR specific amplitude and phase relationships, the position and
dimension relationships of all the coils and the copper sheets
A. Working principle of the sensor are discussed.
Working principle of the sensor is illustrated in Fig.1. B. Position and dimension relationships discussion of the
five coils
The relationships of dimension and position among all these
five coils and the copper sheet could refer to Fig.2. To be easily
observed, the coils are represented by the circles in Fig.2(a). In
the designing process, amplitudes of signals generated by L2 &
L3 and L4 & L5 are equal with each other and the phase
difference is 90 degree.
10 (5)
In (2), |Z|, RL and L are impedance, resistance and inductance 5
sin θ 3 =
of coil L1, respectively. 5
According to the electromagnetic induction, the voltage 10
r = ( + 1 )R
signals generated by one of the smaller planar spiral copper 2
coils under effect of the big coil can be expressed as: If the large coil is located in the original point of the
d Φ 21 dI coordinate system, the center position parameters of the four
u 21 = = -M =
dt dt (3) smaller coils are easily obtained.
- 2 AwM w× L w× L O ( 0 , 0 ,0 )
sin wt − arctan cos( wt − arctan )
RL + ( w × L ) R RL A ( -1 .5 R , 0 .5 R , Z )
2 2
L
(6)
From (3), the four smaller copper coils generate cosine B ( 0 .5 R ,1 .5 R , Z )
voltage signals under effect of L1. M denotes mutual inductance C ( - 0 .5 R ,- 1 .5 R , Z )
coefficient. D (1 .5 R ,- 0 .5 R , Z )
As shown in Fig.1(a), the magnetic filed generated by coil L1
After determining the position and dimension relationships
is affected if there is a conductor such as a copper sheet moving
of the coils in the XOY plane, the distance between the big coil
under the coils. According to the electromagnetic wave
and the smaller coils along Z-axis is discussed.
propagation theory, the electromagnetic wave can be reflected
by the cooper sheet. Therefore, when the copper sheet moves From equation (3), u21 is proportional to M. Therefore, to
under one of the smaller coils, the magnetic flux flowing into it maximize u21, we acquire the maximum value of M. As the
becomes small. Consequently, the mutual voltage u21 is small values of the mutual inductance coefficients of all these four
as shown in equation (3). smaller coils and big coil are the same, only the second coil L2
As shown in Fig.1(b), the amplitudes of the signals are is taken for example in the following analysis.
different when the copper sheet located at different positions. It is known that the planar spiral coil is treated as the
Therefore, as the cooper sheet moving from one side of coil L1 concentric coils approximately. Assuming the distance between
to the other side, the regular signals such as sine and cosine any two neighboring coils of L1 and L2 are Δ1 and Δ2, the
ones are generated. Five typical points in the signal generating concentric coil numbers N1 and N2 of L1 and L2 are calculated as
process are given in Fig.1(b). To ensure all the signals with follows:
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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TIE.2014.2387794, IEEE Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS
primary and secondary coils. If the primary coil is injected with E ij ( k ij ) = E ij ( ρ = π / 2, k ij ) = 1- ∑
2 n =1 2 n !! 2 n − 1
voltage signals, the mutual inductance coefficient M of two
circular circles is calculated as follows: Therefore,
µ R 2π [ p1 cos ϕ + p 2 sin ϕ + p 3 ]Ψ ( k ) nπ k ij 2 π ∞ ( 2 n − 1)!! 2 n
2
Ψ ij ( k ij ) =
(8)
M = 0 S
π ∫
0
dϕ
k V03 2n − 1
− ∑ k ij
(18)
4 n =1 2 n !!
In (8), μ0 is permeability of vacuum. Rs and Rp are radiuses of In the equation above, (x2,y2,z2): center location of the
the secondary and primary coils, respectively. The coordinates smaller coil L2. r: the maximum radius of the coil L1. rj: the
(xC, yC, zC) defining the center of the secondary coil. The radiuses of coils L1, j=1 to N1. Δ1: the radius difference between
secondary coil is located in a plane λ=ax+by+cz+d=0. Other any two neighboring coils of L1. φ: integral cell of the coils.
parameters are expressed as (9). Taking (5), (6) and all the conditions into the equation (10),
yC R y
p1 = ± γ = ± ;p 2 = m β ;p 3 = S ;p 4 = ± γ = ± C ; M is rewritten as follows:
RP RP RP
µ 0 Ri
N N
2π
× ∑ ∑ ∫ ℜdϕ
1 2
x 4V0 M =
p 5 = m β = m C ;k = π j =1 i =1
0
RP A0 + 2V0 (19)
nπ k ij 2π ∞ (2 n − 1)!! n 2
R ρ
2 2 (9) ( ± y 2 cos ϕ m x 2 sin ϕ + Ri )( − )∑ ( k ij )
RS yC x 2n − 1
A0 = 1 + S + +2 ± cos ϕ m C sin ϕ ℜ=
4 n =1 2 n !!
P
R P
R R P R P R P 1
2Vij2
2 b2c2 c2 abc r j 2 + z 2 2 + r j 2Vij2 + 2 r j 2Vij
V0 = α 1 − 2 2 cos ϕ + 2 sin ϕ + 2 sin 2ϕ
2 2 2
L2 is calculated as follows:
M =
π ∫0
ℵdϕ
π 2n − 1 4 n =1 2 n !!
j =1 i =1
0
k V 3
ℵ=
ij ij 1
2V02
In (10), r 2 + z 2 2 + r 2V 02 + 2 r 2V0
Ri = R - ∆2 ( i - 1) i=1 to N 2 (11) The equation (20) is simplified as follows:
μ0: permeability of vacuum which is often used as the ellipticE ( R ,h ,cos ϕ , sin ϕ ) 2π (21)
M =K
permeability of the copper. R: the maximum radius of the coil + ellipticK ( R ,h ,cos ϕ , sin ϕ )
0
L2, Ri: the radiuses of coils L2, i=1 to N2, Δ2: the radius
The relationship between M and h is established through
difference between any two neighboring coils of L2. parameter R. Sampling different points of the ratio h/R in the
The smaller circles are located in a plane λ=ax+by+cz+d=0, θ section [0, 100] and the relationship curve is illustrated in Fig. 3.
is the angle between Z-axis and Z’ axis. In the paper, the plane λ It is known that with the distance increases, the absolute value
is parallel to XOY, the plane expression λ=cz+d=0 and a=b=0, of M decreases. Therefore, if the condition h ≤ 2.4R is satisfied,
θ = 0. Therefore, the other parameters are defined as follows. the distance is as small as possible to maximize the absolute
y value of M. Otherwise, we set h=5R as there is a peak value of
p1 j = ± 2
rj M at this point.
(12)
x2
p2 j = m j=1 to N 1 ,i=1 to N 2
r - ∆1 ( j - 1)
R- ∆2 ( i - 1)
p 3ij =
r - ∆1 ( j - 1)
4V0 (13)
k ij = r j
r j 2 + z 2 2 + r j 2Vij2 + 2 r j 2Vij
Vij2 =
1
rj2
( Ri2 + x2 2 + y 2 2 ± 2 Ri y 2 cos ϕ m 2 Ri x2 sin ϕ ) (14)
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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TIE.2014.2387794, IEEE Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS
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10.1109/TIE.2014.2387794, IEEE Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS
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10.1109/TIE.2014.2387794, IEEE Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS
F. Code Disc The other side of the signal processing board is mainly
Main structure of the code disc is illustrated in Fig.7. N and composed of five parts including MCU(Micro Control Unit),
ROO are acquired according to the requirements of the ADC (Analog to Digital Converter), ASPC(Analog Signal
applications. Then, the other parameters of the outer circle are Processing Circuit), C&P(Communication and Power) part and
calculated as follows: JTAG(Joint Test Action Group). As the analog sine and cosine
LC signals are generated by the inductors, they have to be filtered
N = 2π ROO − 2 L P and changed to single signals from difference ones by ASPC
(28)
part. Then, the signals are converted to digital ones thorough
( OO
W + W OI ) 3
L P = 2
×
2
the ADC. Besides, the digital signal processing and the absolute
In (28), LP is the signal period length of the outer circle. position angle calculation process are undertaken by the MCU.
(WOO+WOI)/2 is the width of the copper sheet of the outer circle At last, the absolute position angle P is transmitted through the
which is about 2/3 of the period length according to experience. C&P part.
Then RIM, the central circle radius of the inner copper sheets, B. Establish The Experimental Platforms
is determined as equation: To test and calibrate the senor system at different rotating
R IM = ( N -1) LP 2π = 3( N -1)(W IO + W II ) 8π (29) speeds, two experimental platforms are established. Fig.10
gives us an illustration to the experimental platform with the
III. DESIGN OF THE SENSOR AND THE EXPERIMENTAL maximum rotating speed is 5 r/min while the high rotating
PLATFORM speed experiment setup which can reach up to 1000 r/min is
shown in Fig.11.
A. Design of The Sensor
Main structure of the sensor can be seen in Fig.9 and two
inductors, the code disc and the signal processing circuit board
constitute the sensor.
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controller. To be easily observed in the testing process, an IV. EXPERIMENTAL RESULTS AND ANALYSIS
oscilloscope (d) is used. Some other necessary components Based on the testing platforms above, the experiments with
such as the power system (c) is elaborated. different rotating speeds are carried out.
In the high-speed experimental platform, a robot joint
labeled (5) in the low part of Fig. 11 is used. An absolute A. Experiment with low rotating speed
magnetic encoder with measuring precision 0.05 degree is In this experiment, rotating speed of the code disc is about
inserted in the joint to measure position of the motor. However, 2.47r/min and the original signals of the sensor are shown in
code disc (2) of the sensor is fixed on the motor output port Fig. 12. The number of the sampling points is 375621 and the
through a clutch (4). Electrical system of the joint (6) is placed total sampling time is about 75.1s. In each circle, the number of
on the platform. Besides, similar to the experimental platform the sampling points is about 121400 and therefore, there are
above, the power system (b), oscilloscope (c) and the signal two integral cycles shown in Fig. 12. Sin1 and Cos1 are the
acquisition system (d) are used. signals of the outer inductor and the others are the inner one’s.
Supply voltage of the inductors is 2.5v and the amplitudes of
the signals are between 0 to 2.5v. Comparing with the same
channel signals of different circles, it is clear that the signals
have better performance on repeatability. Both of the sine and
cosine signals of the same inductor have a similar changing
tendency at the same position.
Items Values
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dCos11 and dSin11 are the fitting signals of Cos11 and Sin11,
respectively.
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takes about 1.0% ratio of the signals. It is also caused by the magnetic sensors. As shown in TABLE II, width of AMRS-1 is
distance error. As the amplitudes of sine and cosine signals vary only 4.5mm which is much smaller than other sensors.
in different cycles, the median values B1 and B2 are different in (2) It is easy-to-integrate. As the inner diameter of AMRS-1
different cycles and consequently, B is not constant in the is with large inner diameter and small width, it is easy to be
whole circle. integrated into the devices with hollow structures such as robot
At last, the phase difference Δp is another parameter which joint.
has effect on the values of the absolute angle. Through signal (3) It is light. Weight of the sensor is only 19g which is only
processing, changing range of the phase difference Δp1 and Δp2 half weight of the other magnetic sensors.
is from 0 to 0.1 radian. In theory, it is a constant value in the (4) Like some of the other magnetic sensors, it has no
whole circle. However, as the manufacturing errors of the requirement to the rotating speed.
copper sheets, the phase differences of sine and cosine are (5) The excitation signals of the sensor is 4MHz and
different in different periods. therefore, it can tolerant to the disturbance and vibration with
From the analysis above, measuring errors of the sensor are frequency of 2MHz which is much higher than the other
mainly caused by the manufacturing errors of the sensor and the commercial sensor.
experimental platform. All the errors are accumulated and lead (6) Similar to the other magnetic sensors, it is robustness and
to the absolute position measurement error reaching up to [-0.5º, tolerance to dust and oil.
+0.5º] which is about 0.27% of the total measurement range. As discussed above, measuring precision of the AMRS-1 is
low comparing with the commercial magnetic sensors listed in
V. CONCLUSION the TABLE II. However, it is only a prototype of the sensor. In
In the paper, a novel absolute magnetic rotary sensor has the developing process, we find some reasons for low
been developed. The output signals are optimized through measuring precision, and some further measures will be taken
analysis of the dimension of the planar spiral copper coils and to improve performance of the sensor. Firstly, design a
the position relationships among the big coil, the smaller coils mechanical structure packaging the sensor to improve the
and the copper sheets. The simulation and experiment results mechanical assembly precision of the sensor. Besides, the
show effectiveness of the sensor. Through calibration with high signal conditioning circuit of the sensor should be optimized.
precision encoders, measuring precision of the sensor is [-0.5º, Then, a parameter identification method will be developed to
+0.5º] which is low comparing with some commercial sensors. identify the phase, amplitude and median value differences
However, it still has some advantages and the detailed among the signals. At last, the calibrating method and devices
parameters comparison with some other commercial absolute will be designed to improve measuring precision of the sensor.
magnetic sensor can be shown in TABLE II. In the table,
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10.1109/TIE.2014.2387794, IEEE Transactions on Industrial Electronics
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS
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no.1, pp.69–80, Jan. 2012.
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