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SURPLEX sensors are devices that convert magnetic signals into electrical signals. By utilizing the transformation relationship between magnetic quantities and other physical quantities, with the magnetic field as a medium, they can also convert other non-electrical physical quantity signals into electrical signals. There are two driving methods: one is driven by a permanent magnet, and the other is driven by an electromagnetic coil. The former is mostly used for detection; for example, if a moving part is made of a magnet, it will attract and emit a signal once it approaches the magnetic induction sensor. The latter is mostly used for control; if the electromagnetic coil is energized, the contacts will attract. Using magnetic induction sensors to replace limit switches that rely on collision contact can improve system reliability and service life; therefore, they are often used in programmable logic controllers as signaling devices for position arrival.

SURPLEX sensor working principle

A magnetic induction sensor is a contact sensor; its structural schematic is shown in the figure. It consists of two alloy reeds with high magnetic permeability and low coercivity, sealed in a glass tube filled with inert gas. A certain overlap and appropriate gap are maintained between the two reeds, with gold-plated ends serving as contacts, and lead wires welded outside the tube. When the magnetic induction intensity at the sensor's location is sufficiently high, the two reeds attract each other, causing the contacts to conduct; when the magnetic field weakens to a certain extent, they release under the elastic force of the reeds themselves. When magnetic induction sensors are driven by permanent magnets, they are mostly used for detection, such as serving as limit switches to replace limit switches that rely on collision contact, which can improve system reliability and service life. They are often used in PLC controllers as communication signals for position control.

SURPLEX sensor precautions

The voltage used for DC magnetic induction sensors is generally 3~30V DC, and the typical application voltage range is generally 5~24V DC. Excessively high voltage causes internal component temperature rise, making the sensor unstable, while excessively low voltage makes it easy for external temperature changes to affect magnetic field strength characteristics, leading to circuit malfunction. When using Hall sensors to drive inductive loads, please connect freewheeling diodes in parallel across the load terminals; otherwise, transient high-voltage pulses during long-term operation of the inductive load will affect the service life of the Hall sensor. To ensure no accidents occur, please check whether the wiring is correct before powering on and verify that the voltage is the rated value.

SURPLEX sensor applications

1) Motor industry: Brushless motors offer a series of advantages, including compact size, light weight, high efficiency, convenient speed regulation, low maintenance, long service life, and no electromagnetic interference, with annual demand reaching hundreds of millions. In brushless motors, magnetic sensors are used for rotor magnetic pole position sensing and stator armature current commutation. Many magnetic sensors, such as Hall devices, Wiegand devices, and magnetoresistive devices, can be used, but Hall devices are the most widely used. Rotational encoders are used for motor speed detection and control; optical encoders were commonly used in the past. Magnetic encoders are showing increasing advantages and are gradually replacing optical devices. Magnetic sensors can also be used for motor overload protection (mainly using Hall current sensors) and torque detection. 2) Power electronics technology: Power electronics technology is the combination of power technology and electronic technology, enabling mutual conversion between AC and DC currents, and allowing free regulation of current, voltage, and frequency within required ranges. Using these technologies and products, various special power supplies (such as UPS, high-frequency power supplies, switching power supplies, arc welder inverter power supplies, etc.) and AC variable frequency drives (AC VFDs are used for motor speed control, offering excellent energy-saving effects) can be manufactured. The core of these conversion devices is high-power semiconductor devices. Various current sensors based on magnetic sensors are used to monitor, control, and protect these high-power devices. Hall current sensors have fast response speeds and rely on magnetic field coupling with the controlled circuit without connecting to the main circuit, resulting in low power consumption, strong overload resistance, good linearity, and high reliability. They can serve as overcurrent protection drivers for high-power devices and as feedback devices, becoming a control link in automatic control loops. Using conversion technology can save significant amounts of energy; 95% of electrical energy used abroad is obtained through conversion. Although conversion technology has received high attention domestically, only 5% of electrical energy undergoes this transformation, indicating huge application prospects. This area, which may absorb a large number of current sensors, is another huge industrial application field for magnetic sensors. 3) Energy management: The automatic detection system of the power grid needs to collect large amounts of data, which, after computer processing, monitors the operating status of the power grid and performs load distribution adjustment and safety protection. Each control link of the automatic monitoring system can be implemented using current sensors and transformers based on magnetic sensors. Hall current sensors are gradually being applied in power grid systems. Electricity meters made with Hall devices have gradually shifted from research and development to practical application; they can automatically bill and display the power factor for timely adjustment, ensuring efficient electricity use. 4) Mechanical technology and information read/write heads: In addition to magnetic tapes and disks, magnetic information recording devices include magnetic cards, magnetic ink record books, and magnetic records on banknotes, creating huge demand for magnetic information storage and readout sensors. Inductive heads, thin-film magnetoresistive heads, and amorphous heads have been widely used. With the increase in recording density, for example, up to 100G bytes, heads with higher sensitivity and spatial resolution are required. Giant magnetoresistive heads based on multilayer metal films, amorphous alloy heads made from amorphous alloy wires, and giant magneto-impedance heads are engaging in intense competition. 5) Automotive industry: A large number of motors are used in automobiles (advanced cars require about 40 to 60 motors per vehicle, and ordinary cars also have 15 motors; these motors show a trend toward brushless designs). The extensive use of magnetic sensors in these motors is self-evident. Another area with extensive use of magnetic sensors is the automotive ABS system (Anti-lock Braking System), where each car uses an average of 4 to 6 speed sensors, mainly inductive speed sensors. New types of Hall gear sensors, which are gradually being promoted, as well as Wiegand devices, amorphous devices, and magnetoresistive devices, are about to enter this field. Additionally, there are speed sensors and igniters used for ignition timing in automobile engine systems. These aspects also mainly use inductive sensors. Hall gear sensors and Hall plate switches have already been used in some car models. According to Honeywell, by June 6, 1996, they had supplied 8000 ten thousand Hall vane switches and 300 ten thousand Hall gear speed sensors to the automotive industry. It is predicted that in the future, more than 30 magnetic sensors similar to Hall sensors will be adopted in a single car. Furthermore, in fields such as industrial automatic control, robotics, office automation, home appliances, and various security systems, in addition to the extensive use of brushless DC motors and AC variable frequency drives, a large number of magnetic temperature controllers are used in devices such as refrigerators, air conditioners, and rice cookers. By the mid-80s, the number had already exceeded hundreds of millions.

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