Hall position sensor

• US 6,497,035 B1
• Filed: 01/14/2000
• Issued: 12/24/2002
• Est. Priority Date: 12/06/1999
• Status: Expired due to Term

• Current Assignee: HR Textron, Inc.
• Original Assignee: HR Textron, Inc.
• Inventors: Ratliff, William Edward
• Primary Examiner(s): Strecker, Gerard R.
• Application Number:
  US09/483,302
• Time in Patent Office: 1,075 Days
• Field of Search: 324/117.H, 324/173, 324/174, 324/207.2, 324/207.21, 324/235, 324/251, 324/252, 307/116, 361/749, 361/760, 338/32.R, 338/32.H, 174/117.F, 174/117.FF, 174/254, 298/54, 298/57, 298/60, 295/96, 439/67, 439/77, 310/71, 310/68.B
• US Class Current: 29/596
• CPC Class Codes: G01B 7/003 for measuring position, not involving coordinate determination coordinate measuring G01B7/004
• CPC Class Codes: G01B 7/023 for measuring distance between sensor and object G01B7/082 and G01B7/102 take precedence
• CPC Class Codes: G01D 11/245 Housings for sensors
• CPC Class Codes: G01D 5/145 influenced by the relative movement between the Hall device and magnetic fields see G01R33/06
• CPC Class Codes: G01D 5/147 influenced by the movement of a third element, the position of Hall device and the source of magnetic field being fixed in respect to each other
• CPC Class Codes: G01R 33/07 Hall effect devices
• CPC Class Codes: H01R 12/592 connections to contact elements
• CPC Class Codes: H02K 11/215 Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 15/0006 Disassembling, repairing or modifying dynamo-electric machines repairing of cooling fluid boxes H02K15/0093
• CPC Class Codes: H02K 2203/03 Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations
• CPC Class Codes: H02K 2211/03 Machines characterised by circuit boards, e.g. pcb
• CPC Class Codes: H02K 23/00 DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors
• CPC Class Codes: H02K 26/00 Machines adapted to function as torque motors, i.e. to exert a torque when stalled
• CPC Class Codes: H02K 29/08 using magnetic effect devices, e.g. Hall-plates, magneto-resistors H02K29/12 takes precedence
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H05K 1/118 specially for flexible printed circuits, e.g. using folded portions
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49179 : by metal fusion bonding

Abstract

An improved Hall position sensor comprises a Hall effect sensing device having its leads soldered directly to an exposed electro-conductive portion of a flexible multiconductor circuit. The Hall position sensor further comprises a Hall magnet disposed proximate to the soldered Hall effect sensing device/flexible circuit unit.

Claims

1. A method of manufacturing a brushless motor including a stator and a rotor and a Hall magnet carried by said rotor and having a Hall sensor for detecting the position of said rotor, said method comprising the steps of:

(a) providing at least one fully flexible circuit having first and second ends and including at least one electrical contact area containing exposed electrical conductors;

(b) providing a surface mount Hall effect sensing device having a plurality of electro-conductive leads;

(c) soldering said plurality of electro-conductive leads of said surface mount Hall effect sensing device directly to said exposed electrical conductors of said at least one fully flexible circuit;

(d) operatively positioning said Hall effect sensing device on said stator adjacent said Hall magnet;

(e) providing a controller for said motor; and

(f) coupling said Hall effect sensing device to said controller with said fully flexible circuit.

2. A method of manufacturing a brushless motor as defined in claim 1 wherein said exposed electrical conductors are at said first end of said fully flexible circuit.

3. A method of manufacturing a brushless motor as defined in claim 2 wherein said second end of said fully flexible circuit is coupled to said controller.

4. A method of manufacturing a brushless motor as defined in claim 3 which includes the further step of adhesively securing said Hall effect sensing device and said fully flexible circuit to said motor adjacent said first end thereof.

5. A method of manufacturing a brushless motor as defined in claim 3 which includes the further step of positioning said controller remote from said motor.