Design Optimization of PCB-Based Rotary-Inductive Position Sensors

This paper introduces a novel methodology to optimize the design of a ratiometric rotary inductive position sensor (IPS) fabricated in printed circuit board (PCB) technology. The optimization aims at reducing the linearity error of the sensor and amplitude mismatch between the voltages on the two receiving (RX) coils. Distinct from other optimization techniques proposed in the literature, the sensor footprint and the target geometry are considered as a non-modifiable input. This is motivated by the fact that, for sensor replacement purposes, the target has to fit a predefined space. For this reason, the original optimization technique proposed in this paper modifies the shape of the RX coils to reproduce theoretical coil voltages as much as possible. The optimized RX shape was obtained by means of a non-linear least-square solver, whereas the electromagnetic simulation of the sensor is performed with an original surface integral method, which are orders of magnitude faster than commercial software based on finite elements. Comparisons between simulations and measurements performed on different prototypes of an absolute rotary sensor show the effectiveness of the optimization tool. The optimized sensors exhibit a linearity error below 0.1% of the full scale (FS) without any signal calibration or post-processing manipulation.