Rotary transformer

A rotary transformer, also known as a resolver, works on the principle of electromagnetic induction to transfer electri-
cal signals between a rotating and stationary part without physical contact. It consists of a stator (stationary part)
and a rotor (rotating part), with windings on both. When an alternating current (AC) is applied to the stator winding
(primary), it creates a magnetic eld that induces a voltage in the rotor winding (secondary). The induced voltage
varies depending on the rotor's angular position, making it useful for position sensing applications

The rotary transformer is essentially the same as a conventional transformer, except that the geometry is arranged so
that the primary and secondary can be rotated, with respect to each other with negligible changes in the electrical
characteristics. The most common of the rotary transformers are the axial rotary transformer, shown in Figure, and
the at plane, (pot core type), rotary transformer, shown in Figure. The power transfer is accomplished, electro-
magnetically, across an air gap. There are no wearing contacts, noise, or contamination problems due to lubrication
or wear debris.

Working Principle
A rotary transformer works like a normal transformer, but its primary and secondary coils can move relative to each
other. As the angle between them changes, the output signal's amplitude changes, but the frequency stays the same.
Typically, it produces two output signals with sine and cosine wave shapes, which help in measuring rotation angles.
To measure angles, two rotary transformers (one for sine, one for cosine) are usedone sends the signal and the other
receives it. This setup helps determine rotation accurately.

Proximity Sensor
A Proximity Sensor is a type of sensor that detects the presence or movement of objects without physically touching
them. It works by converting the detected presence or movement into an electrical signal.
Types of Proximity Sensors (Based on Detection Method)

Inductive Proximity Sensors

An Inductive Proximity Sensor detects metallic objects without contact by sensing changes caused by eddy currents.
The sensor has a coil that generates an AC magnetic eld. When a metal object comes close, the magnetic eld induces
eddy currents in the object. These eddy currents cause energy loss, which changes the impedance (AC resistance) of
the coil. The sensor detects these impedance changes and outputs a signal.
Capacitive Proximity Sensors
Capacitive Proximity Sensors detect changes in the capacitance between the sensing object and the Sensor. The
amount of capacitance varies depending on the size and distance of the sensing object. An ordinary Capacitive
Proximity Sensor is similar to a capacitor with two parallel plates, where the capacity of the two plates is detected.
One of the plates is the object being measured (with an imaginary ground), and the other is the Sensor's sensing
surface. The changes in the capacity generated between these two poles are detected. The objects that can be
detected depend on their dielectric constant, but they include resin and water in addition to metals.

Magnetic Proximity Sensors

Magnetic proximity sensors are designed for non-contact position detection and provide longer sensing ranges than
inductive sensors. They operate using a separate damping magnet to detect position and are capable of sensing
through various materials, including non-ferrous metals, stainless steel, aluminum, plastic, and wood. These sensors
are widely used in industries such as food processing, where they can detect cleaning devices inside pipes.

Depending on the magnetic eld orientation, they can sense magnets from either the front or the side. Their output
comes in two main types: linear, where the output voltage is directly proportional to the magnetic eld strength, and
binary, where the sensor switches between ON and OFF states based on whether the eld strength crosses a specied
threshold.

This versatility makes them highly reliable replacements for mechanical switches, as they have no moving parts
and are less prone to wear or failure.
Advantages
Replace mechanical switches (no moving parts, no wear/jam issues).

Highly reliable.

Hall-eect
The Hall-eect refers to the electrical potential dierence across a conducting or semi-conducting material when it
is subjected to a magnetic eld perpendicular to the direction of the current ow. As current passes through the
conductor, the magnetic eld will bend the electrons to one side, creating a voltage dierence across the conductor's
surface.

Hall-eect rotary position sensor

A Hall-eect rotary position sensor typically consists of:

Magnetic disk  xed to a rotating shaft

Stationary Hall-eect IC  positioned close to the disk

Working
As the shaft rotates, the magnetic eld from the disk changes relative to the sensor. The Hall IC detects these changes
as variations in Hall voltage (proportional to magnetic eld strength and polarity). The sensor electronics process this
voltage into an angular position signal. This allows the sensor to output the absolute angular position of the shaft
relative to a reference point. The output of a rotary Hall-eect sensor is a voltage that changes in direct proportion
to the shaft angle. The sensor is non-contact, using Hall elements to determine the angle of a magnet. The magnet
can either be integrated with the shaft or mounted externally to the sensor.

Hall-eect rotary position sensors provide a good balance of accuracy and resolution. Since they contain no internal con-
tacting parts, they are free from the wear and tear seen in mechanical/contacting sensors, leading to much longer rota-
tional life spans.

Torque Transducer
A torque transducer is a sensor that measures and converts torque (the twisting force that causes rotation) into an
electrical signal. Most torque transducers employ foil-type strain gauges bonded to a torque-sensitive diaphragm or
shaft. When torque is applied, the material deforms slightly, causing the strain gauges to stretch or compress. This
changes their electrical resistance, which is detected using a Wheatstone bridge circuit. The bridge output is then
amplied and conditioned, providing a calibrated torque reading as an analog or digital signal.

Types of Torque Transducers:

There are two main types of torque measurements:

1. Reaction Torque
Reaction torque transducers measure torque loads where the sensor does not rotate (or rotates only slightly). Typical
applications include motor or pump torque, valves, actuators, steering gears, and gear reducers.

2. Rotary Torque
Rotary torque transducers measure torque in rotating systems such as motors, crankshafts, gearboxes, or turbines.
Since the shaft is spinning, the signal must be transmitted from the rotating element to stationary electronics. This
is achieved either by slip rings or by non-contact methods.

Slip Ring Rotary Torque Sensors

Working Principle:

Slip ring sensors use physical contact between the rotating shaft and stationary electronics. Strain gauge signals are
carried via slip rings and brushes. Pros: - Simple, well-established, and relatively low cost - Robust design, suitable
for moderate speeds and loads Cons: - Wear and tear of brushes and rings (requires maintenance) - Limited lifespan
and possible electrical noise - Not ideal for very high-speed applications Applications: Industrial machinery testing,
drivetrain evaluation, mixers, conveyors, and other mid-speed, cost-sensitive setups.

Non-Contact Rotary Torque Sensors

Working Principle: Non-contact sensors use inductive coupling, rotary transformers, or wireless telemetry to transfer
strain-gauge signals without physical contact. Advanced versions employ Surface Acoustic Wave (SAW) technology,


where distortion of SAW devices on the shaft alters their resonant frequency, detected wirelessly by RF pickups. Pros:
- No wear longer lifespan and low maintenance - Higher accuracy with reduced signal noise - Suitable for high-speed
and high-cycle applications Cons: - Higher cost - More complex electronics Applications: High-performance environ-
ments such as aerospace, Formula 1 gearbox/engine testing, renewable energy (wind turbines), and pharmaceutical
manufacturing requiring precise torque monitoring.