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Machine Learning-Driven Sensitivity Analysis for a 2-Layer Printed Circuit Board Inductive Motor Position Sensor.

Qinghua Lin1, Devin Sullivan2, Douglas Moore1

  • 1CTS Corporation, 905 W Blvd. North, Elkhart, IN 46514, USA.

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|February 13, 2026
PubMed
Summary
This summary is machine-generated.

This study introduces a two-layer printed circuit board (PCB) routing strategy for compact inductive motor position sensors. The novel approach ensures accuracy within ±1 electrical degree across various installation tolerances, crucial for electric vehicle traction motors.

Keywords:
Fourier seriesSHapley Additive exPlanationsaccuracyextreme gradient boostinginductive motor position sensormachine learningrouting strategy

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Area of Science:

  • Automotive Engineering
  • Electrical Engineering
  • Sensor Technology

Background:

  • Traction motor control in electrified powertrains relies on precise motor position sensors.
  • Increasingly compact motor designs create significant packaging constraints for these sensors.

Purpose of the Study:

  • To present a novel two-layer (2L) printed circuit board (PCB) routing strategy for inductive motor position sensors in space-limited applications.
  • To analyze the accuracy and identify dominant error sources in sensor performance under varying installation conditions.

Main Methods:

  • Fabrication and testing of a prototype sensor with a comprehensive design of experiments (625 combinations of offsets, tilt, and airgap).
  • Accuracy analysis using Fourier series and development of an Extreme Gradient Boosting (XGBoost) model (R² = 0.9951) for error prediction.
  • Application of SHapley Additive exPlanations (SHAP) to identify key error drivers and their interactions.

Main Results:

  • Sensor accuracy remained within ±1 electrical degree across all tested installation tolerances.
  • DC offset and magnitude mismatches were identified as dominant error contributors due to routing modifications.
  • Tilt angle and Y-offset were found to be the primary drivers of accuracy degradation, with a strong coupled influence (interaction intensity = 0.9581).

Conclusions:

  • The developed 2L PCB routing strategy effectively maintains high accuracy for inductive motor position sensors in restricted spaces.
  • The study highlights the non-linear nature of installation-induced accuracy degradation and provides a framework for sensor layout optimization and tolerance establishment.