Search Results (68)

Measuring weak magnetic fields proposes significant challenges to the sensing capabilities of magnetic field sensors. The magnetic field detection capacity of tunnel magnetoresistance (TMR) sensors is often insufficient for such applications, necessitating targeted optimization strategies to improve their performance in weak-field measurements. Utilizing magnetic flux concentrators (MFCs) offers an effective approach to enhance TMR sensitivity. In this study, the finite element method was employed to analyze the effects of different MFC geometric structures on the uniformity of the magnetic field in the air gap and the magnetic circuit gain (MCG). It was determined that the MCG of the MFC is not directly related to the absolute values of its parameters but rather to their ratios. Simulation analyses evaluated the impact of these parameter ratios on both the MCG and its spatial distribution uniformity, leading to the formulation of MFC design optimization principles. Building on these simulation-derived principles, several MFCs were fabricated using the 1J85 material, and an experimental platform was established to validate the simulation findings. The fabricated MFCs achieved an MCG of 7.325 times. Based on the previously developed TMR devices, a detection sensitivity of 2.46 nT/$\sqrt{\mathrm{Hz}}$ @1Hz was obtained. By optimizing parameter configurations, this work provides theoretical guidance for further enhancing the performance of TMR sensors in magnetic field measurements. Full article

Mechanical defects and sensor failures can substantially undermine the reliability of low-cost sensors, especially in applications where measurement inaccuracies or malfunctions may lead to critical outcomes, including system control disruptions, emergency scenarios, or safety hazards. To overcome these challenges, this paper presents a novel Self-X architecture with sensor redundancy, which incorporates dynamic calibration based on multidimensional mapping. By extracting reliable sensor readings from imperfect or defective sensors, the system utilizes Self-X principles to dynamically adapt and optimize performance. The approach is initially validated on synthetic data from tunnel magnetoresistance (TMR) sensors to facilitate method analysis and comparison. Additionally, a physical measurement setup capable of controlled fault injection is described, highlighting practical validation scenarios and ensuring the realism of synthesized fault conditions. The study highlights a wide range of potential TMR sensor failures that compromise long-term system reliability and demonstrates how multidimensional mapping effectively mitigates both static and dynamic errors, including offset, amplitude imbalance, phase shift, mechanical misalignments, and other issues. Initially, four individual TMR sensors exhibited mean absolute error (MAE) of 4.709°, 5.632°, 2.956°, and 1.749°, respectively. To rigorously evaluate various dimensionality reduction (DR) methods, benchmark criteria were introduced, offering insights into the relative improvements in sensor array accuracy. On average, MAE was reduced by more than 80% across sensor combinations. A clear quantitative trend was observed: for instance, the MAE decreases from 4.7°–5.6° for single sensors to 0.111° when the factor analysis method was applied to four sensors. This demonstrates the concrete benefit of sensor redundancy and DR algorithms for creating robust, fault-tolerant measurement systems. Full article

Touch is a crucial sense for advanced organisms, particularly humans, as it provides essential information about the shape, size, and texture of contacting objects. In robotics and automation, the integration of tactile sensors has become increasingly relevant, enabling devices to properly interact with their environment. This study aimed to develop a biomimetic, skin-inspired tactile sensor device capable of sensing applied force, characterizing it in three dimensions, and determining the point of application. The device was designed as a 4 × 4 matrix of tunneling magnetoresistive sensors, which provide a higher sensitivity in comparison to the ones based on the Hall effect, the current standard in tactile sensors. These detect magnetic field changes along a single axis, wire-bonded to a PCB and encapsulated in epoxy. This sensing array detects the magnetic field from an overlayed magnetorheological elastomer composed of Ecoflex and 5 µm neodymium–iron–boron ferromagnetic particles. Structural integrity tests showed that the device could withstand forces above 100 N, with an epoxy coverage of 0.12 mL per sensor chip. A 3D movement stage equipped with an indenting tip and force sensor was used to collect device data, which was then used to train neural network models to predict the contact location and 3D magnitude of the applied force. The magnitude-sensing model was trained on 31,260 data points, being able to accurately characterize force with a mean absolute error ranging between 0.07 and 0.17 N. The spatial sensitivity model was trained on 171,008 points and achieved a mean absolute error of 0.26 mm when predicting the location of applied force within a sensitive area of 25.5 mm × 25.5 mm using sensors spaced 4.5 mm apart. For points outside the testing range, the mean absolute error was 0.63 mm. Full article

In response to the accurate positioning issue for high-speed moving lens groups in rapid zoom optical lenses with voice coil motors (VCMs), we demonstrate a positioning system design based on tunnel magnetoresistance sensors. The equivalent magnetic charge method and finite element method (FEM) simulations were utilized to compute the magnetic field distribution of the magnetic grating encoder. Based on analytical computation, the optimal air gap δ_S between the sensor and magnetic grating is determined to be δ_S = 0.15 mm, which balances magnetic flux density amplitude and total harmonic distortion. In addition, a simplified fitting model is proposed to reduce computational complexity. We quantify the magnetic interference of VCM through three-dimensional flux leakage mapping by FEM analysis, deriving an optimal sensor position O_S, with a 24 mm y-offset and 20 mm z-offset relative to the VCM’s origin O_V. The position error caused by interference remains below 5 μm with maximum deviations at trajectory endpoints of the moving group. The original signal output is processed and corrected, and eventually, the measured displacement exhibits a linear relationship with actual displacement. Our study provides a comprehensive framework for the design and optimization of magnetic positioning systems in optical applications with electromagnetic motors. Full article

Accurate measurement of magnetic fields holds immense significance across various disciplines, such as IC circuit measurement, geological exploration, and aerospace. The sensitivity and noise parameters of magnetic field sensors play a vital role in detecting minute fluctuations in magnetic fields. However, the current detection capability of tunneling magnetoresistance (TMR) is insufficient to meet the requirements for weak magnetic field measurement. This study investigates the impact of structural and fabrication parameters on the performance of TMR sensors. We fabricated series-connected TMR sensors with varying long-axis lengths of the elliptical cross-section and adjusted their performance by modifying annealing magnetic fields and magnetic field bias along the easy axis. The results demonstrate that TMR sensitivity decreases with increasing long-axis length, increases initially and then decreases with an annealing magnetic field, and decreases with a higher bias magnetic field along the easy axis. The voltage noise level of TMR sensors decreases as the long-axis length increases. Notably, the detection capability of TMR sensors exhibits a non-monotonic dependence on long-axis length. Moreover, we optimized the hysteresis of TMR sensors by applying a magnetic field bias along the easy axis. When the bias along the easy axis reached 16 Oe or −40 Oe, the hysteresis level was reduced to below 0.5 Oe. After encapsulating the TMR devices into a full Wheatstone bridge structure, we achieved a detection capability of 17 nT/$\sqrt{\mathrm{Hz}}$@1Hz. This study highlights that the detection capability of TMR devices is jointly influenced by fabrication parameters. By optimizing parameter configuration, this work provides theoretical guidance for further enhancing the performance of TMR devices in magnetic field measurements. Full article

With the rapid development of current sensor technology, tunnel magnetoresistance (TMR) current sensors have been widely adopted in industrial detection due to their high sensitivity, excellent linearity, and broad measurement range. This study focuses on closed-loop TMR current sensors, utilizing COMSOL Multiphysics 6.2 software and the finite element method to conduct an in-depth analysis of structural parameters affecting sensor sensitivity. A novel magnetic shielding package architecture is proposed and designed. Simulation results demonstrate that the shielding efficiency of this structure improves by 44.3% compared to a single magnetic ring under a stray magnetic field of 0.1 mT along the sensing axis. At the same time, the measurement accuracy is 2.1 times higher than that of traditional structures. Current detection experiments conducted in a strong magnetic field environment further validate that the shielding package effectively suppresses external electromagnetic interference, significantly enhancing sensor stability and measurement accuracy. This research provides important theoretical and practical insights for applying high-precision TMR current sensors in complex electromagnetic environments. Full article

To meet the demand for high-precision, high-resolution measurement of weak currents in smart grids, this article presents the design of a current sensor based on the tunneling magnetoresistance (TMR) effect. To improve the detection accuracy of the sensor, this design adopts a low-noise, high-sensitivity TMR chip as its chip selection; in the sensor circuit, a high-linearity interface circuit is used to eliminate fixed bias; and a magnetic flux concentrator is used to improve sensitivity and anti-interference capability. Experimental results indicate that the sensor achieves a sensitivity of 29.4 mV/V/mA, a linearity of 0.19%, and an accuracy of 0.045% within a ±100 mA range, supporting current measurement from DC up to 10.5 kHz. The proposed sensor demonstrates several advantages, including a wide measurement range, high accuracy, high resolution, and non-invasive measurement capability, making it well suited for weak current detection in smart grid applications. Full article

Surface quality control of hot-dip galvanized sheets is a critical research topic in the metallurgical industry. Zinc dross, the most common surface defect in the hot-dip galvanizing process, significantly affects the sheet’s service performance. In this manuscript, a novel magnetic flux leakage (MFL) detection method was proposed to detect zinc dross defects on the surface of hot-dip galvanized steel sheets. Instead of using exciting coils in traditional methods, a tiny permanent magnet with a millimeter magnitude was employed to reduce the size and weight of the equipment. Additionally, a high-precision tunnel magnetoresistance (TMR) sensor with a sensitivity of 300 mV/V/Oe was selected to achieve higher detection accuracy. The experimental setup was established, and the x-axis direction (sample movement direction) was determined as the best measurement axis by vector analysis through experiments and numerical simulation. The detection results indicate that this novel MFL detection method could detect industrial zinc dross with an equivalent size of 400 μm, with high signal repeatability and signal-to-noise ratio. In the range of 0–1200 mm/s, the detection speed has almost no effect on the measurement signal, which indicates that this novel method has higher adaptability to various conditions. The multi-path scanning method with a single probe was used to simulate the array measurement to detect a rectangular area of 30 × 60 mm. Ten zinc dross defects were detected across eight measurement paths with 4 mm intervals, and the positions of these zinc dross defects were successfully reconstructed. The research results indicate that this novel MFL detection method is simple and feasible. Furthermore, the implementation of array measurements provides valuable guidance for subsequent in-depth research and potential industrial applications in the future. Full article

Tunnel magnetoresistance (TMR) sensors, known for their high sensitivity, efficiency, and compact size, are ideal for detecting weak currents, particularly leakage currents in smart grids. However, temperature variations can negatively impact their accuracy. This work investigates the effects of temperature variations on measurement accuracy. We analyzed the operating principles and temperature characteristics of TMR sensors and proposed a high-precision, software-based temperature compensation method using cubic spline interpolation combined with polynomial regression and zero-point self-calibration. Additionally, a field-programmable gate array (FPGA)-based temperature compensation circuit was designed and implemented. An experimental platform was established to comprehensively evaluate the sensor’s performance under various temperature conditions. Experimental results demonstrate that this method significantly enhances the sensor’s temperature stability, reduces the sensitivity temperature drift coefficient, and improves zero-point drift stability, outperforming other compensation methods. After compensation, the sensor’s measurement accuracy in complex temperature environments is substantially improved, enabling effective weak current detection in smart grids across diverse environments. Full article

The sensitivity of Tunnel Magnetoresistance (TMR) sensors is characterized by significant temperature drift and poor sensitivity drift repeatability, which severely impairs measurement accuracy. Conventional temperature compensation techniques are often hindered by low compensation precision, inadequate real-time performance, and an inability to effectively address the issue of poor repeatability in temperature drift characteristics. To overcome these challenges, this paper introduces a novel method for suppressing temperature drift in TMR sensors. In this method, an alternating reference magnetic field is applied to TMR sensors, and the output amplitude at the frequency of the reference magnetic field is calculated to compensate the sensitivity temperature drift in real time. Temperature characteristic tests were conducted in a non-magnetic temperature test chamber, and the results revealed that the proposed method significantly reduced the TMR sensitivity drift coefficient from 985.39 ppm/°C to 59.08 ppm/°C. Additionally, the repeatability of sensitivity temperature characteristic curves was enhanced, with a reduction in root mean square error from 0.84 to 0.21. This approach effectively mitigates temperature-induced sensitivity drift without necessitating the use of a temperature sensor, and has the advantages of real-time performance and repeatability, providing a new approach for the high-precision temperature drift suppression of TMR. Full article

In technology and industrial production, many applications require wide-bandwidth current measurements. In this paper, a signal fusion scheme for a current sensor comprising tunneling magnetoresistance and a current transformer is proposed, achieving a flat frequency response in the DC to MHz range. The measurement principles in different cases of the scheme are introduced, and the total transfer function of the entire scheme is derived by analyzing each section separately. Furthermore, the feasibility and selected parameters of the scheme are verified through a systematic simulation utilizing the MATLAB software. Based on the proposed scheme, a group of principal prototypes are built to experimentally evaluate the bandwidth, amplitude and phase flatness, accuracy, sensitivity, and impulse response. The relative amplitude variation in the passband of the fusion sensor is less than 4%, and the estimated bandwidth of the fusion sensor is close to 17 MHz. The accuracy is better than 0.6%, even when measuring the current at 1 MHz, and the relative standard deviation is 5% when measuring the impulse signal. The sensors developed using this scheme, with a low financial cost, have advantages in many wide-bandwidth current measuring scenarios. Full article

This study proposes a high-resolution rotation-measuring system for miniaturized MEMS ultrasonic motors using tunneling magnetoresistance (TMR) sensors for the first time. Initially, the architecture and principle of the rotation-measuring system are described in detail. Then, the finite element simulation is implemented to determine the miniaturized permanent magnet’s residual magnetization, dimensions, and TMR sensor position. Finally, the experiments are implemented to evaluate the performance. Using calibration based on a high-precision servo motor, it is found that the relationship between the output and rotational angle is highly linear and immune to the rotor’s out-of-plane movement. Meanwhile, the angle-detecting resolution is higher than 0.1°. After the calibration, the continuous rotation of the MEMS ultrasonic motor is tested. It is found that the angle testing result varies with a period close to 360°, which indicates that the rotation-measuring system has successfully detected the motor’s rotation. Full article

In response to the zooming delay issue during the transition from a wide-area search to high-resolution target identification in high-magnification zoom lenses, we propose a drive technology based on voice coil motors. The linear motion of the motor is directly converted into the linear movement of the zoom lens group, significantly enhancing the zoom speed. Additionally, we introduce a high-precision closed-loop control technology utilizing a magnetic scale to achieve the rapid and precise positioning of the zoom lens group. The magnetic scale detection technology achieves precise positioning by detecting periodic changes in the magnetic field, working in conjunction with tunnel magnetoresistance sensors. Demonstrated with a 40× zoom lens example, this study elaborates on the motion trajectory planning and structural dimension design process of a voice coil motor, culminating in the assembly of a physical prototype. Practical validation experiments show that the full zoom time of the lens utilizing our technology is less than 0.3 s, where the full zoom time refers to the time required for the lens to zoom from the wide-angle end to the telephoto end. In positioning accuracy test experiments, lenses using our technology achieved a positioning deviation of less than 5 μm. Full article

The main objective of the work is to investigate the capacity of a single magnetoresistance (MR) element to measure AC electrical currents. An instrumentation system is presented to characterize individually the four active elements of an MR bridge current sensor preserving their internal connections. The system suggests the possibility to sense electrical currents using only one element of the bridge opening the way to design new MR sensors based on this concept. Sensitivity, offset and non-linearity deviation were obtained using bridges of tunnel (TMR)- and giant (GMR)-based MR technologies. The single element embedded in a Wheatstone bridge configuration is used for practical current measurements in a 50 Hz line. An electronic circuitry is proposed to measure alternating (AC) currents with a single MR element, including a lock-in amplifier and an interface to properly convert the signal to its root mean square (rms) value with a resolution of 250 mA peak in the 125 A range. Full article

Ferromagnetic pipes are widely used in the oil and gas industry. They are subject to cracks due to corrosion, pressure, and fatigue. It is significant to detect cracks for the safety of pipes. A residual magnetic field testing (RMFT) system is developed for crack detection in ferromagnetic pipes. Based on this background, a detection probe based on an array of tunneling magneto-resistive (TMR) sensors and permanent magnets is exploited. The probe is able to partially magnetize the pipe wall and collect magnetic signals simultaneously. First, a theoretical analysis of RMFT is presented. The physics principle of RMFT is introduced, and a finite element model is built. In the finite element simulations, the effects of the crack length and depth on the RMFT signal are analyzed, and the signal characteristics are selected to represent the crack size. Next, the validated experiments are conducted to demonstrate the feasibility of the proposed RMFT method in this paper. Full article