Design and Non-Linearity Optimization of a Vertical Brushless Electric Power Steering Angle Sensor

This paper presents the design and the non-linearity optimization of a new vertical non-contact angle sensor based on the electromagnetic induction principle. The proposed sensor consists of a stator part (with one solenoidal excitation coil and three sinusoidal receiver coils) and a rotor part (with six rectangular metal sheets). The receiver coil was designed based on the differential principle, which eliminates the effect of the excitation coil on the induced voltage of the receiver coil, and essentially decouples the excitation field from the eddy current field. Moreover, the induced voltages in the three receiver coils are three-phase sinusoidal signals with a phase difference of 10 degrees, which are linearized by CLARK transformation. To minimize the sensor non-linearity, the Plackett-Burman technique was used, which identified the stator radius and the rotor blade thickness as the key factors affecting the sensor linearity. Then, the particle swarm algorithm with decreasing inertia weights was utilized to optimize the sensor linearity. A sensor prototype was made and tested in the laboratory, where the experimental results showed that the sensor non-linearity was only 0.648% and 0.645% in the clockwise and counterclockwise directions, respectively. Notably, the non-linearity of the sensor was less than -0.696% at different speeds.