Sensor types | Speed sensors for transmission control
Speed sensors for
transmission control
Application
Transmission speed sensors determine
the shaft speeds in AT, ASG, DKG and
CVT transmissions. These are the turbine
and output shaft speeds on AT transmis-
sions with a hydrodynamic torque con-
verter, the speed of the primary and sec-
ondary pulleys in CVT transmissions and
the speeds of the two input shafts and the
driven shaft of double-clutch transmis-
sions. The speed of the power take-up
element is also detected for high dynamic
demands on power take-up control.
Direction of rotation detection can also
be necessary in high-end transmissions in
order to optimize clutch management and
for rollback prevention.
Both stand-alone sensors and sensors
built into electronics modules which proj-
ect into the transmission from the outside
or are mounted internally are used.
Requirements
Transmission speed sensors are exposed
to very severe operating stresses because
of
• Extreme ambient temperatures between
-40 and +150 °C
• An aggressive operating environment
caused by the transmission oil, also
known as ATF (contains special addi-
tives for transmissions and has a low
condensate content)
• High mechanical stress with vibrational
accelerations up to 30 g
• Abraded metallic materials and a build-
up of particles in the transmission
The package of the electronics used in the
sensor is hence subject to high demands
as a consequence of these severe stresses.
A service life of more than 15 years in
transmission oil has been achieved by
using a suitable oil-resistant package.
249
Because of the very compact design of the
transmissions, the mechanical customer
interface cannot generally be covered
by standard geometries. This means that
custom sensor types are needed for each
transmission model. Module-integrated
types differ in respect of insertion length,
direction of recording and mounting
flange (Fig. 1). A further variation found
in stand-alone sensors is the location of
the mounting socket and the design of
the connector.
Hall ASICs (Application Specific Inte-
grated Circuit) with varying complexities
of the evaluation algorithms are used to
cover the complete range of the functional
requirements (Fig. 2).
If a ferromagnetic trigger wheel or
a trigger area (toothed, stamped or em-
bossed) is available on the rotating trans-
mission component, the magnetic field
required to operate the Hall sensor is
generated by a back-bias magnet.
1 Sensor types
a
1
b c
1 1
Fig. 1
a Bottom read
b Side read
SAE1081Y
c Slant read
1 Direction of
detection
250 Sensor types | Speed sensors for transmission control

It is mounted in the sensor immediately Operating principle

behind the ASIC. Transmission speed sensors use the differ-
Compact transmissions increasingly ential Hall effect. The difference between
require speed measurement over greater the Hall voltages from two Hall plates on
distances (magnetic air gap) by rotating, the ASIC is determined. The majority of
nonmagnetic components or through a the similar interferences can be compen-
housing wall. Multipole wheels (magne- sated for in this way. The difference signal
tized rings) are used for these applica- is first amplified on some ASIC types,
tions, the back-bias magnet is omitted then converted into a digital signal by
from the sensor. trigger algorithms of varying complexities.
This constitutes the controlled variable for
Design modulating the output current by means
The Hall ASICs used in the transmission of a power source. A digital signal with
speed sensors are mounted in a retainer two current levels (typically 7 mA for the
with or without a back-bias magnet –
depending on the magnetic interface –
with the electrical contact being made 3 Hall sensor with two-wire current interface

by a welding process, then inserted in

a housing, potted with epoxy resin or – in IS US
the case of types mounted on the outside
of the transmission – have an oil-tight en- UV
RM URM
closure sprayed onto them (Fig. 3).
The sensor has a two-wire interface,
which combines optimum diagnostic op-
tions with a minimum number of electrical
connections. The two terminals both sup-
ply the Hall IC and transmit the signal.

SAE0907-1Y

2 Requirements complexity

Vibration immunity
Direction of rotation detection

High speed range Vibration suppression

Sensor requirement

Speed accuracy Additional third Hall area

Air gap changes Higher cycle frequency

Large Noise suppression

air gap
area Switching threshold tracking

Offset tracking Multiplier tracking

SAE1082E

ASIC complexity
 Sensor types | Speed sensors for transmission control 251

low level and 14 mA for the high level) is
obtained, the modulation frequency of
which corresponds to the frequency of
tooth change on the trigger wheel and
thus represents the speed of rotation.
The sensor signal is evaluated in the elec-
tronic control unit by means of a measur-
ing shunt RM, which converts the sensor
current IS into the signal voltage URM.
On principle, it does not matter for
the operation of a differential Hall ASICs
whether the sensor is operated with a
steel trigger wheel or on a multipole
wheel (Figs. 4a and 4b).
4 Transmission speed sensor operating principle
a Rotation
1 achievable (distance between the sensitive
L C R
2
3 c
b Rotation
4
N S N
L C R
2 and the functional requirements leads to
Some transmission controls include func-
tions that require detection of a standstill.
For this application, the sensor must have
as great an immunity as possible against
vibration-induced variations in the air gap
and the torsional vibration of the trigger
wheel. This property of the sensor, known
as immunity against vibration, can only
be implemented to a very limited degree
in differential Hall sensors with only two
Hall plates, by the use of adaptive trigger
thresholds, for example. Two phase-
shifted differential signals become avail-
able with the use of a third Hall plate.
This makes both the detection of the di-
rection of rotation (Figs. 4c to f) and addi-
tional function algorithms for increasing
immunity against vibration possible.
The typical values for “value” and “high Fig. 4
feature” sensors differ in the air gap range a Configuration with
trigger wheel
area on the sensor and the trigger wheel), b Configuration with
the signal frequency range and the addi- multipole wheel
Sensor signal
tional functionalities implemented (Table 1).
(difference signal
between Hall plates
The complexity of transmission type, R and C)
mounting space restrictions including d Sensor signal
all the derived marginal design conditions (difference signal
between Hall plates

application-specific solutions in most ap- C and L)

c
e Output signal for
plications. These are characterized by a
Difference

R-C clockwise rotation

combination of ASIC, package design and
signal

f Output signal for

sensor mechanical and magnetic interface counterclockwise
suitable for the system requirements. rotation
d
Difference

C-L 1 Trigger wheel

2 Hall plates L and
signal

R (C optional
for direction of
5 1 Typical characteristics rotation detection)
e
Type Value High feature 3 Permanent magnet
(back-bias)
Maximum air gap
Output
signal

4 Multipole wheel
at trigger wheel 2.5 mm 3.5 mm
5 Phase shift
at pole wheel 5 mm 7 mm
dependent on
f Signal frequency 0 to 8 kHz 0 to 12 kHz
the direction of
Direction of rotation No Yes
SAE1083E

rotation
detection
Output
signal

Trigger wheel – ± 1.5°

vibration Table 1