An assembly line is essential for preparing all effect sensors. A versatile automatic line allows cutting and bending the sensors to prepare the sensors before they are soldered to electronic circuits. Hall-effect sensors exploit the Hall effect to detect and measure the presence of a magnetic field.

When a magnetic field passes through the material, a signal is given by the sensor that generates a voltage in the image of the current to be displayed or measured. Hall-effect sensors is intended for various applications, particularly in the automotive, precision mechanics and aeronautics industries. The high mechanical resistance of the sensors allows them to be installed on different types of devices. They are generally used as rotation, displacement, speed or position sensors.

Hall-Effect Sensor Application

In the industrial field, the sensor is used to detect the displacement and position of various elements. It allows the automation of various machines and production lines. In order to increase their efficiency, integrators can automate their production process by installing a sensor on their machines.

In the automotive sector, the Hall-effect sensor can be used to determine the direction of rotation of a component, for motor control or battery management. Used as a current sensor, it is also present in automotive converters. These are used to control the traction motor of electric or hybrid cars. The currents flowing through a conductor generate the magnetic field that is converted by the sensor into a programmable voltage. The voltage is proportional to the detected magnetic field.

It should be noted that Hall-effect sensors are very present in robotics and production lines.

Hall-Effect Sensor Assembly

For industrial applications, manufacturers deliver the sensors in strips of tens or hundreds of components. These must be cut and bent to be operational. The use of a dedicated machine for this purpose is then essential so that the sensors take the necessary shape before they are soldered onto the electronic circuits.

This machine can be integrated into an automated production line and offers several configuration possibilities. It allows high quality cuts and preforms to be obtained.

The sensor assembly line in particular is composed of several stations connected by a pallet conveyor and positioned in a “U” shape. It is designed to make production more flexible. Thus, it is possible to adjust the workforce as required.

The assembly of the Hall-effect sensors is sequenced by semi-automatic operations. Before thermode micro welding at the end of the line, the components are placed, butt welded and checked.

Sensor Testing and Control

The use of a test bench is essential in order to carry out the control of the sensors. It is, in fact, a semi-automatic equipment allowing the programming and the electrical control of the Hall-effect sensors intended to detect the position of the gearbox lever of a vehicle.

A gasket is placed on the product by the operator using a gasket mounting clamp. It positions the connector and the sensor cup on the test cassette. The start of the cycle of the automatic tests of non-electrical characteristics is initiated by the action of the push button. These non-electrical characteristics concern the presence and color of the gasket, the beam length and the insert.

Using an RLC bridge, capacitance measurements and electrical controls are performed by a PC. Thanks to the movement of a target driven by a rotating precision table, signals are obtained allowing the programming of the cell by the PC. Then, a micro-percussion marking is carried out on each conforming product. The cassettes used on the test bench are interchangeable.