Numerical Investigation of Halbach-Array-Based Flexible Magnetic Sensors for Wide-Range Deformation Detection

Flexible magnetic tactile sensors hold great promise for wearable electronics and intelligent robotics but often suffer from limited strain range and complex magnetic field variations due to rigid-soft coupling between the Hall sensor and magnetic layer. In this study, we propose a Halbach-array-based magnetic tactile sensor that structurally decouples the soft magnetic deformation layer from the rigid Hall sensing unit. The sensor embeds k = 2 Halbach-configured magnetic cubes within a PDMS matrix, while the Hall element is fixed at a remote, rigid location. Numerical analysis using COMSOL Multiphysics demonstrates that the Halbach configuration enhances magnetic field strength and uniformity, achieving mT-level detection even at a distance of 15 mm. Moreover, the Halbach array effectively reduces the field distribution from three-dimensional to one-dimensional, enabling stronger directionality, simplified data processing, and higher sensing frequency. This work establishes a theoretical framework for wide-range, high-precision magnetic tactile sensing through magnetic field tailoring, providing valuable guidance for the design of next-generation flexible sensors for wearable, robotic, and embodied intelligence applications.