Improving the Angular Velocity Measured with a Low-Cost Magnetic Rotary Encoder Attached to a Brushed DC Motor by Compensating Magnet and Hall-Effect Sensor Misalignments
This paper proposes a method to improve the angular velocity measured by a low-cost
magnetic rotary encoder attached to a brushed direct current (DC) motor. The low-cost magnetic
rotary encoder used in brushed DC motors use to have a small magnetic ring attached to the rotational
axis and one or more fixed Hall-effect sensors next to the magnet. Then, the Hall-effect sensors
provide digital pulses with a duration and frequency proportional to the angular rotational velocity
of the shaft of the encoder. The drawback of this mass produced rotary encoder is that any structural
misalignment between the rotating magnetic field and the Hall-effect sensors produces asymmetric
pulses that reduces the precision of the estimation of the angular velocity. The hypothesis of this
paper is that the information provided by this low-cost magnetic rotary encoder can be processed
and improved in order to obtain an accurate and precise estimation of the angular rotational velocity.
The methodology proposed has been validated in four compact motorizations obtaining a reduction
in the ripple of the estimation of the angular rotational velocity of: 4.93%, 59.43%, 76.49%, and
86.75%. This improvement has the advantage that it does not add time delays and does not increases
the overall cost of the rotary encoder. These results showed the real dimension of this structural
misalignment problem and the great improvement in precision that can be achieved.This research was funded by the Spanish Ministry of Science and Innovation, grant number PID2020-118874RB-I00
