Rotary Position Sensors Preforming Tool

Rotary position sensors preforming tool forms and cuts angular sensors to be welded to an electronic circuit. The rotary position sensors collect a signal of the measured angle, so they can detect the position of an element such as, for example, the level of the fork of a forklift.

There are 4 major technologies of rotary position sensors:

  • Potentiometer: which makes it possible to measure an angular displacement limited by the potentiometer itself whose mobile part will be then coupled with the part which one wishes to measure the displacement and whose fixed part will be attached to the frame supporting the mobile part. The amplitude of the displacement is then measured by the variation in resistance of the potentiometer between one of the two fixed limits and the mobile cursor.
  • Resolver: this is a sort of small rotary transformer with a primary and two secondaries offset by 90° electrically. A sinusoidal voltage is fed to the primary and two sinusoids, phase-shifted by 90°, are found in the secondary, whose phase shift with the primary is the image of the angular position to be measured. Depending on the angle between the primary and the two secondaries, there is a variation in the flux induced by the primary towards the secondaries. Thus, the resolver returns the angular position information in the form of two sinusoidally varying voltages.
  • Optical encoder: which always returns digital information.This information most commonly comes from an optical device that includes a light source, a photodetector and a grooved disc. The optical encoder can be linear or rotary, depending on the type of movement to be measured. The rotary encoder measures angular displacement using a disc with striations. The linear encoder measures longitudinal displacement using a transparent scale.
  • Hall effect: Angular displacement is measured using Hall effect sensors.

An angular position sensor has several applications: it can detect the position of elements, the dimensional control and the motion study.


Testing Sensors Before their Use


Angular position sensors are tested and programmed in the laboratory. For this purpose, a test bench is required. This allows hall sensors to be programmed at speeds ranging from 100 to 10,000 RPM. The test bench, from which the test is carried out, consists of a shaft line driven by a motor which is controlled by a test PC that allows the rotation of targets at a maximum speed of 10,000 Rpm.

In order to detect any drift or mis-mounting of the target, the vibration level is monitored during operation and the shaft line is balanced. The angular position of the shaft is provided to the PC by a 36,000 pts/rev incremental encoder so that the signals from the sensor under test are synchronised with the angular position of the target.


Angular Position Sensors with Hall Effect Technology

We are interested in position sensors with Hall effect technology, which allows us to measure the variations between magnetic fields. When a conductive element is introduced into an electromagnetic field, a force proportional to the fields and the current is put in place.

The Hall effect sensor then transmits a signal when the magnetic field is detected. It is therefore mainly used as a position or speed sensor.

Hall effect angular sensors are cheaper and more robust than optical encoder sensors.


Rotary Position Sensor Preforming Tool


The preforming tool bends and cuts Hall effect sensors to be able to be welded to electronic circuits.

Two types of machine tools are present on the market:

  1. Manual machine tool: the sensor is bent by the force of the operator via a crank handle. A manual machine is inexpensive and is intended for schools and prototyping machines that require speed or position sensors. The manual machine allows you to understand how to preform sensors so It is a wonderful teaching tool.
  2. Automatic machine tool: it can be easily integrated in a production line and allows a more precise bending and cutting. The automatic machine is flexible and can preform and cut most of angular position sensors. The production rate is multiplied with a minimized waste rate. For example, the MGA Technologies cutting and bending machine can preform up to 900 sensors per hour.


Technical Characteristics of the MGA Technologies Machine Tool

The MGA Technologies machine tool is flexible: it can be configured as shuttle, bucket or conveyor belt. It can be integrated in an automated manufacturing line and can be interconnected with or several other existing machines in your premises.

Technical characteristics of the MGA Technologies preforming tool:

  • Cadence of 900 angular sensors / hour,
  • Power supply: 110V to 230V,
  • Noise level below 70 dB,
  • Bending accuracy: <2 °,
  • Cutting precision: + – 0.1 mm,
  • Preform magnetic and non-magnetic sensors with 3 to 5 pins,
  • Multilingual interface.

Integration in an Assembly Line


The MGA Technologies rotary position sensor preforming tool is flexible, which allows you to integrate it into any production tool.

Indeed, MGA Technologies has been specialized for nearly 40 years in the design, installation and commissioning of custom-made machine tools for the pharma, agri-food, precision engineering, aerospace and automotive sectors.

The company’s achievements include an automatic vaccine manufacturing line, a diagnostic card assembly machine, an automatic kit preparation line, a pharmaceutical filter transfer machine and many others. Throughout their project, MGA Technologies’ customers can count on a dedicated team to support them.

Do you need a sensor cutting and bending machine and want to integrate it into your production tool? Request a brochure via our form or contact our technical teams directly to obtain more information about our expertise and obtain a personalized quotation.

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