A new sensor provides full-range motor position tracking, interference resistance, and safety for high-speed control in electric vehicle systems.
TDK Corporation has introduced the HAL 3025, a Hall-effect position sensor designed for x-by-wire motor control systems in applications. The sensor combines 360° contactless angle measurement, ASIL D-ready functional safety, and stray-field immunity in a single-die architecture aimed at reducing system complexity and cost.
The HAL 3025 is built for motor control applications operating at up to 60,000 rpm, including steer-by-wire, brake-by-wire, and traction systems. Using TDK-Micronas’ SixSense technology, the device measures the vertical magnetic field component to determine absolute rotational position while suppressing external DC and AC magnetic interference in line with ISO 11452-8 standards.
That stray-field compensation is important in electric motor designs where power electronics sit close to the sensing element. By reducing sensitivity to electromagnetic interference, the sensor eliminates the need for magnetic shielding or larger magnets. TDK says a two-pole ferrite magnet mounted in an end-of-shaft configuration is sufficient.
Unlike redundant multi-die safety sensors, the HAL 3025 uses a single-die failsafe architecture developed as an SEooC ASIL D-ready solution under ISO 26262. The approach is intended to simplify ECU design, reduce board space, and lower bill-of-material costs while maintaining diagnostic coverage. Integrated monitoring functions include wire-break detection and overvoltage and undervoltage protection, enabling fault detection and reducing the amount of external supervision required.
The sensor outputs differential or single-ended sine and cosine analog signals, allowing external microcontrollers or ECUs to calculate absolute angular position with high resolution. Its analog signal chain is optimized for low latency and high bandwidth, both of which are critical in fast-response powertrains and safety-related actuators.
To support manufacturing calibration, the HAL 3025 includes programmable non-volatile memory for adjusting signal-path parameters such as gain, offset, orthogonality, 0-angle alignment, and magnetic bandwidth. These settings can be configured through the output pin, removing the need for programming interfaces.
Target applications include brushless DC motors, permanent magnet synchronous motors, AC induction motors, steering rack and steering wheel actuators, electrohydraulic and electromechanical braking systems, and high-voltage traction motor systems.
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