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Proportional Integral (PI) controllers are a fundamental component in modern control systems, widely used to enhance performance and mitigate steady-state errors. They are particularly effective in applications such as automatic brightness adjustment on smartphones, where they excel at mitigating steady-state errors for step-function inputs. Unlike PD controllers, which require time-varying errors to function optimally, PI controllers leverage their integral component to address residual...

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Updated: Sep 5, 2025

The Modular Design and Production of an Intelligent Robot Based on a Closed-Loop Control Strategy

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Published on: October 14, 2017

Design Optimization of PCB-Based Rotary-Inductive Position Sensors.

Aldi Hoxha¹, Mauro Passarotto¹, Gentjan Qama²

¹EMCLab, Polytechnic Department of Engineering and Architecture, University of Udine, 33100 Udine, Italy.

Sensors (Basel, Switzerland)

|July 9, 2022

Summary

This study presents a new method to optimize printed circuit board inductive position sensors (IPS). The technique enhances sensor linearity and reduces coil voltage mismatch, achieving high accuracy without calibration.

Keywords:

absolute encoders digital resolvers eddy currents inductive position sensors (IPS)non-linear least-squares sensor optimization surface integral method

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Area of Science:

Electrical Engineering
Sensor Technology
Electromagnetics

Background:

Ratiometric rotary inductive position sensors (IPS) are crucial for precise angular measurement.
Existing optimization methods often lack flexibility due to fixed sensor footprints and target geometries.
Linearity error and amplitude mismatch in receiving coils degrade sensor performance.

Purpose of the Study:

To develop a novel optimization methodology for PCB-based ratiometric rotary IPS.
To minimize linearity error and amplitude mismatch in the sensor's receiving coils.
To adapt optimization for non-modifiable sensor footprints and target geometries.

Main Methods:

Utilizing a non-linear least-square solver to determine optimal receiving (RX) coil shapes.
Employing a fast, original surface integral method for electromagnetic simulations.
Considering fixed sensor footprints and target geometries as constraints.

Main Results:

Achieved significant reduction in linearity error, below 0.1% of full scale (FS).
Minimized amplitude mismatch between the two RX coils.
Demonstrated effectiveness through comparison of simulations and measurements on prototypes.

Conclusions:

The proposed optimization technique effectively enhances the performance of PCB-based rotary IPS.
The method allows for sensor redesign within existing mechanical constraints.
Optimized sensors provide high accuracy without the need for calibration or post-processing.