Light-Weight and Compact Magnetic Rotation Angle Sensor with Partial Arc Stator Using Three Hall-Effect Sensors

In this paper we propose a compact magnetic rotation angle sensor which comprises a permanent magnet, Hall-effect sensors, and partial arc-shaped stator located in a large-diameter traction motor to reduce the size and weight of automotive vehicles. The proposed rotation angle sensor removes a specific harmonic component of the leakage flux from the electric motor by converting the signal from three-phase to two-phase using three Hall-effect sensors. The design concept of the rotation angle and its magnetic design results are shown in this study. A prototype of the proposed rotation angle sensor was created and its weight, size, and magnetic performances were measured. The measurement results achieved a 38 and 33 % weight and volume reduction, respectively, compared with a conventional variable reluctance resolver. Furthermore, the experimental results demonstrated that the angle position of the motor can be detected in line with the electromagnetic design and target of the angle error.