Intelligent Fault Detection in Hall-Effect Rotary Encoders for Industry 4.0 Applications

Abstract

Sensors are the foundational components of any smart machine system and are invaluable in all modern technologies. Consequently, faults and errors in sensors can have a significant negative impact on the setup. Intelligent, lightweight, and accurate fault diagnosis and mitigation lie at the crux of modern industries. This study aimed to conceptualize a germane solution in the domain of fault detection, focusing on Hall-effect rotary encoders. Position monitoring through rotary encoders is essential to the safety and seamless functioning of industrial equipment such as lifts and hoists, and commercial systems such as automobiles. This work used multi-strategy learners to accurately diagnose quadrature and offset faults in Hall-effect rotary encoders. The obtained dataset was then run through a lightweight ensemble classifier to train a robust fault detection model. The complete mechanism was simulated through interconnected models simulated in a MATLAB Simulink™ environment. In real time, the developed fault detection algorithm was embedded in an FPGA controller and tested with a 1 kW PMSM drive system. The resulting system is computationally inexpensive and achieves an accuracy of 95.8%, making it a feasible solution for industrial implementation.

A Sage–Husa Prediction Algorithm-Based Approach for Correcting the Hall Sensor Position in DC Brushless Motors

“…As we dug deeper into the research by various experts in the field, it was clear that different strategies have been proposed to address deviations and errors introduced by the Hall sensor installation, demagnetization of permanent magnets, and motor parameters’ changes due to prolonged operation. Ritik Agarwal [ 16 ] developed a motor model using Simulink to determine if there exists an offset of the position sensor and quadrature error of the permanent magnet in a permanent magnet synchronous motor (PMSM) used in an elevator scheme with a 4-phase HALL sensor. The model explores the influence of sensor mounting deviation and the quadrature deviation of the permanent magnet on the motor control parameters.…”

Capacitive Angle Sensor Research Using COMSOL Multiphysics

“…The measurement of absolute angle plays an important role in positioning and mechanical engineering; it is also widely used in the automotive industry and aerospace and machine manufacturing [1][2][3]. To measure an absolute angle using non-contact sensing, full circle measurement range, high resolution and high precision, rotary encoders are needed [4][5][6].…”