The OEM part here was very complicated having a circuit board, and several pieces almost like a Chinese puzzle. No good support for the Hall Effect sensor, and difficult to apply potting compound.
Implemented a design using fewer plastic parts (fewer expensive molds), just a base with insert molded conductors, and a plastic cap. The bas provided a positive location and support for the Hall Effect IC during soldering and when applying the cap. Also a mounting fixture for the magnet between the dual sensors. A stamped and formed steel flux guide concentrator was created to guide the magnetic flux through the Hall Effect elements in the ICs. . |