Design And Calibration For Hall Based Brake Pedal Rotary Sensor

The rotary position sensor is one of the key parts of automotive ECU system,it is massively used in vehicle chassis,engine and transmission systems.The actuation and safety of vehicle's systems are deeply impacted by sensor's reliability.This thesis mainly discusses the design and research works for dual brake pedal rotary sensor with contactless technology in tractor pedal system.At first,the benchmark analysis is introduced for main global sensor producers and give the design direction for the contactless of through hole rotary sensor.The Comsol software is used to implement the simulation for magnetic circuit design to get the output signal curve for rotary sensor and vector potential map.Meanwhile,the material for magnet and shielding ring is discussed.Secondly,the sensor mechanical structure is analyzed.The output signal linearization is improved by the magnet shape change.The simulation is also performed to check the output signal for the conditions of relative position moving of magnet and axial rotary in assembly.In addition,the sensor manufacturing process is discussed to ensure the right position of sensor inside components by low pressure molding plus high pressure overmolding.At last,the sensor calibration fixture is designed to program and test the sensor.By the analysis of output data,the sensor output accuracy is calculated including linearity,repeatability,hysteresis and result in stray field.The testing result is to show that this hall rotary sensor can meet all requirements in tractor brake pedal system.