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Methode Electronics - non-contact sensor technology

EUROBIKE, 27 - 30 August 2014. Magnetoelastic patented non-contact sensor technology at LEV Components Special Exhibition.

A few years ago the market for torque sensor was limited to only a few applications. Mainly for testing and measurements under lab-conditions where straingauge-based solutions are being used due to their outstanding precision.

High costs and limited performance of straingauge sensors in challenging environments are the main reasons, why the torque which is essential for control and regulation of transmissions, was being calculated indirectly through other measurement values (e. g. pressure).

The industrialization of the magnetoelastic (inverse magnetostrictive) principle opens new ways and creates new applicationsand markets for torque and force sensors. E-bikes are the best example demonstrating this development.

Technology Fundamentals
Methode's patented non-contact sensor technology utilizes fundamental mechanical and magnetic properties of the material to measure different process parameters. The process involves measuring changes in the properties of remnant magnetic fields as the mechanical characteristics change, such as shear stress, as external forces are applied onto the sensor host.

The technology is applied by directly magnetizing a mechanical member instead of attaching additional elements, such as a ring. Highly sensitive fluxgate sensors located in close proximity to the magnetized member sense the change in the magnetic-field characteristics that are proportional to the applied force. These changes are linear and repeatable within the elastic limit of the material, and are accurate under normal and extended operating conditions. Even though the underlying principle utilizes the theory of magnetoelasticity, Methode enhances the efficiency by developing and patenting magnetic profiles that eliminate certain known shortcomings of magnetoelasticity, increasing its versatility and uses.

Torque measurement has been previously achieved primarily through either a strain gauge or phase-shift approach, which limited the applications for engineers and required mathematical solutions to estimate torque. Methode now provides a commercially viable measurement of torque either in an axial or radial direction. Methode's magnetoelastic technology can function on any size substrate whether it is rotating at high speeds or not at all. Through patented enhancements to the fundamental magnetoelastic technology, Methode can now provide robust measurements without the use of costly shielding for challenging EMI conditions and maintain very high accuracy. Typically this measurement is used as a discrete input or as a critical measurement for closed-loop control within a larger system.

Technical details
Range: 0 to +/- 1Nm or 0 to +/- 50 kNm
Resolution: 0.1 Nm to 0.5 Nm
Accuracy: 0.5% to 1.0%
Repeatability: 0.25% to 0.4%
Response to Change: 1kHz to 20kHz
Substrate: 6.0mm to 600mm
Operating Temperature: -40C to 180C
Power Required: <15mA

Magnetizing the shaft, target or gear tooth allows for the measurement of speed without applying a permanent target to the shaft. Methode's sensor offers a small footprint, an easy design installation; the ability to measure through a nonferrous membrane or wall, such as a housing; and can be placed in potentially explosive environments.

A simple two-wire connection provides a commonly accepted signal output. The greater value is when the speed sensor is incorporated as part of a torque or absolute-angle sensor. The magnetic profile and housing then becomes common, mitigating the cost of two or three different devices, and reducing space, weight and customer product assembly.

>> Product photos (flickr)

Customer Values

  • Maintenance-free throughout the design life of the product
  • Enhanced product performance and design-in simplicity
  • Product differentiation
  • Reduce warranty and catastrophic failure
  • Achieve ever-changing industry and regulatory requirements
  • High accurate torque direct measurement
Technology Values
  • Contactless sensing, No sensor wear or recalibration throughout
  • the design life
  • Total immersion in caustic fluids, high temperature, impact and vibration
  • Meet challenging ergonomic, environmental performance and cost objectives
Get in touch with Methode Electronics International GmbH:

Tel.: 0049 6725-3095-0

>> info@methode.com

>> www.methode.com

About the LEV Components Special Exhibition
The LEV Components Special Exhibition is an easy way to get a quick overview on LEV components offered by suppliers from all over the world.

In 2014, the LEV Components Special Exhibition has been shown at Taipei Cycle Show/Taiwan, CeBIT/Germany, China Cycle Show/China, Battery Conference/Germany, and VivaVelo Conference/Germany. Upcoming shows are EUROBIKE/Germany, INTERMOT/Germany, eBikeTec/Germany and Challenge Bibendum/China.

How to participate

Potential exhibitors interested in participating at the  following trade shows can receive further details and booking conditions from Isabel Wolf (Project Coordinator) at:

>> Isabel.Wolf@ExtraEnergy.org

>> Details and booking form (PDF)

Please find further background information on the LEV Components Special Exhibition here:

>> LEV Components Special Exhibition - World Premiere

Follow the event on Facebook:

>> EUROBIKE: LEV Components Special Exhibition

Text: ExtraEnergy Services GmbH & Co. KG, Methode Electronics International GmbH. The product information is the respective company´s own and does not necessarily represent ExtraEnergy´s editorial policy.

Pictures: Methode Electronics International GmbH

8 August 2014



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