Hall Effect Sensor Assembly Line

The hall effect sensor uses the hall effect to measure and detect the presence of a magnetic field. A signal is given by the sensor when a magnetic field passes through the material. It then generates a voltage that reflects the current to be measured or visualized. It is intended for various applications in particular in the field of aeronautics, precision mechanics or the automotive industry. The robustness of the sensors allows them to be installed on various devices. They can be used as speed, position, displacement or rotation sensors. However, to be usable, they must be cut and bent before being soldered to electronic circuits. The assembly of the hall effect sensors must be carried out on a versatile automatic line.

Types of Hall Effect Sensors


  • Linear Hall effect sensors

In the automotive sector and for more complex design, Hall effect sensors are most commonly used for the detection of transmission speed change. They can also be used as liquid level sensors to detect the location of the moving float.

  • Digital Hall Effect Sensors

Because digital Hall sensors are so flexible, they can be programmed to activate at a given magnetic field tolerance. In addition, they are best suited to meet precise detection requirements. For high-speed detection, digital Hall sensors are most commonly used in white goods such as washing machines and dryers.

Digital Hall sensors are particularly useful in automotive safety applications. They provide high reliability for seat belt buckle tightening detection and transmission tooth speed detection.

  • Rotary Hall Effect Sensors

The use of rotary Hall effect sensors to replace film or potentiometer devices has become increasingly popular. In the applications of various household appliances, they can also be used to detect the position of the dial. It is also possible to find rotary Hall effect sensors in automotive applications to detect the position of the EGR valve present in the engines.

  • Analog sensors

In the past, the flux density of the magnets could be measured with analog Hall sensors, which are considerably influenced by the temperature value of the application. Nowadays, these sensors have improved significantly so that they can be used to measure the flux field angle while being less sensitive to temperature variations. The output of analog Hall sensors has therefore become more stable due to this improvement.


Application of Hall Effect Sensors


In the automobile sector, for example, the hall effect sensor can be used for motor control, battery management or to determine the direction of rotation of a component. It is also present in automotive converters as a current sensor. These converters are used to drive the traction motor of hybrid or electric cars. The magnetic field generated by the currents flowing through a conductor is converted by the sensor into a programmable voltage. This voltage is proportional to the detected magnetic field.

The sensor can also detect the position and movement of different elements in the industrial field. As a result, it allows the automation of production lines and various machines. For companies wishing to automate their production process for more efficiency, the installation of a sensor on their machines is a necessity.

It is worth noting that hall effect sensors are the most commonly used in production lines as well as in robotics.

Hall Effect Sensor Assembly


The sensors are delivered by the manufacturers in strips of tens or hundreds of components, mainly for industrial applications. In order for them to be operational, it is essential to use a machine to cut and bend them so that they take the necessary shape before soldering them onto electronic circuits.

This machine can be integrated into an automated production line. Not only does it provide high quality preforms and cuts, but it also offers several configuration options.

As far as the sensor assembly line is concerned, it consists of several stations positioned in a “U” shape which are connected by a pallet conveyor. It is designed to make production more flexible. The number of workers can be adjusted according to needs. Semi-automatic in-line operations sequence the assembly of the hall effect sensors. Microsoldering by thermodynamics is carried out at the end of the line, but before that the components are installed, controlled and riveted.


Sensor Inspection and Testing

To ensure the control of the sensors, a test bench is required. This test bench is designed to program and perform an electrical control of hall effect sensors that can be used to detect the position of a car’s gearbox lever. This equipment is semi-automatic.

Using a gasket mounting clamp, the operator places a gasket on the product. They then position the sensor bucket and the connector on the test cassette. The automatic tests of non-electrical characteristics are first started by pressing the push button for the cycle start. These non-electrical characteristics relate in particular to the insert, the length of the beam, the presence and colour of the beam.

Electrical controls and capacity measurements are performed by a PC using an RLC bridge. The signals that are obtained by moving a target driven by a rotating precision table allow the PC to program the cell. A micro-percussion marking is then carried out on each compliant product. It should be noted that the cassettes used on this test bench are interchangeable.

MGA Technologies: a Brief Overview


MGA Technologies is specialized in all aspects of the automation of all production, assembly, inspection and testing processes. On behalf of our many customers, we have designed and built various assembly lines and test benches for the control and programming of hall effect sensors.

If you are interested in a test bench for sensor programming or a hall effect sensor assembly line, contact us today. Here are our contact details…

Discover a sample of our solutions on this page. To find out more about our machine for bending Hall effect sensors, receive a brochure via our form or directly request a quote from our technical team.

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