Design of linear magnetic position sensor used in permanent magnet linear machine with consideration of manufacturing tolerances

Sarbajit Paul, Junghwan Chang, Arvind Rajan, Subhas Mukhopadhyay

Research output: Contribution to journalArticleResearchpeer-review

Abstract

This paper proposes the design of a linear magnetic position sensor (LMPS) to detect the mover position of the permanent magnet linear synchronous machines (PMLSMs). The working principle of the LMPS is based on the well-known Hall-Effect. The Hall-Effect-based design of LMPS is considered because it provides a low cost and relatively harsh environment susceptible alternative for the position detection for long track PMLSM system. The initial design was performed using 3D-finite element analysis and genetic algorithm-based deterministic optimization. Based on the initial model, four LMPS were manufactured and tested under the output constraint of peak flux density > 0.1T and total harmonic distortion < 3%. From the test results, it is concluded that the manufactured LMPS suffered significant deviation in output compared to the simulation model. These anomalies arise because of the manufacturing tolerances. To further improve the design and manufacturing process of the LMPS considering the effect of tolerance, a reliability-based robust design optimization (RBRDO) of the LMPS is proposed. The results of RBRDO confirms its usefulness for the design process of the LMPS in terms of undesired design non-compliance cost and great robustness without sacrificing the accuracy of the output signal.

LanguageEnglish
Pages5239-5248
Number of pages10
JournalIEEE Sensors Journal
Volume19
Issue number13
DOIs
Publication statusPublished - 1 Jul 2019

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permanent magnets
Permanent magnets
manufacturing
sensors
Sensors
Hall effect
design optimization
output
Harmonic distortion
Costs
genetic algorithms
Genetic algorithms
Fluxes
Finite element method
flux density
anomalies
costs
deviation
harmonics
optimization

Cite this

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title = "Design of linear magnetic position sensor used in permanent magnet linear machine with consideration of manufacturing tolerances",
abstract = "This paper proposes the design of a linear magnetic position sensor (LMPS) to detect the mover position of the permanent magnet linear synchronous machines (PMLSMs). The working principle of the LMPS is based on the well-known Hall-Effect. The Hall-Effect-based design of LMPS is considered because it provides a low cost and relatively harsh environment susceptible alternative for the position detection for long track PMLSM system. The initial design was performed using 3D-finite element analysis and genetic algorithm-based deterministic optimization. Based on the initial model, four LMPS were manufactured and tested under the output constraint of peak flux density > 0.1T and total harmonic distortion < 3{\%}. From the test results, it is concluded that the manufactured LMPS suffered significant deviation in output compared to the simulation model. These anomalies arise because of the manufacturing tolerances. To further improve the design and manufacturing process of the LMPS considering the effect of tolerance, a reliability-based robust design optimization (RBRDO) of the LMPS is proposed. The results of RBRDO confirms its usefulness for the design process of the LMPS in terms of undesired design non-compliance cost and great robustness without sacrificing the accuracy of the output signal.",
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Design of linear magnetic position sensor used in permanent magnet linear machine with consideration of manufacturing tolerances. / Paul, Sarbajit; Chang, Junghwan; Rajan, Arvind; Mukhopadhyay, Subhas.

In: IEEE Sensors Journal, Vol. 19, No. 13, 01.07.2019, p. 5239-5248.

Research output: Contribution to journalArticleResearchpeer-review

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