Methode Sensor Technology

Possibilities

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Methode is . . . possibilities

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Methode continues to encourage

a culture of forward thinking

innovation to ensure we remain

at the forefront of our industry

so our customers can remain at

the forefront of theirs.

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Methode Sensor SolutionsMethode is a pioneer in engineering sensing solutions that encompass electromechanical, magnetic, field-effect, optical and biometric technologies for the most challenging requirements. Our broad portfolio addresses diverse applications including: life science and medical equipment, controls for harsh environments and safety critical X-by-wire sensors. We bring these solution to the global market through efficient, multi-industry certified, vertically integrated manufacturing on three continents.

Our broad sensor portfolio

addresses diverse

applications including:

life science and medical

equipment, controls for

harsh environments and

safety critical X-by-wire

applications.

Sensor Portfolio Highlights

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Magnetoelastic SolutionsA patented solution utilizing the mechanical and magnetic properties of a target material. Vertically-integrated fluxgates measure changes in the properties of remnant magnetic fields as external forces are applied to the target material.

Range Resolution Accuracy (full scale)

Repeatability Response to Change

Substrate Operating Temp

Power Required

Torque 0 to +/-1Nm0 to +/-50 kNm

0.1 Nm to 0.5 Nm

0.5% to 1.0% 0.25% to 0.4%

1kHz to 20kHz

6.0mm to 600mm

-40C to 180C <15mA

Linear Position

<1 mm to 33 mm 0.1 mm to 0.5 mm<

0.5% to 1.0% 0.25% to 0.4%

1kHz to 20kHz

6.0mm to 600mm

-40C to 180C <15mA

Speed <1 rpm to 25,000 rpm

0.1 rpm 0.5% to 1.0% 0.25% to 0.4%

1kHz to 20kHz

-40C to 180C <15mA

Abs. Angle

0.1 degree to 360 degrees

1 degree to 4 degrees

0.5% to 1.0% 0.25% to 0.4%

1kHz to 20kHz

-40C to 180C <15mA

Load & Force

<1 lbs to 20 tons 0.25 lbs to 1 lbs 0.5% to 1.0% 0.25% to 0.4%

1kHz to 20kHz

6.0mm to 600mm

-40C to 180C <15mA

Level application specific

application specific

0.5% to 1.0% 0.25% to 0.4%

1kHz to 20kHz

-40C to 180C <15mA

Multi-Turn Steering Angle Sensor using Capacitive TechnologyUtilizing relative phase shifts to determine angular displacements between the fixed PCB and the rotating reflectors.

StorageTemperature Range

Operating Temperature Range

Response Time

Rotational Speed

Diameter Length Width Thickness

Resolution

Accuracy

Range

Abs. Angle

-40C to 125C

-40C to 80C

<4 ms 2000 °/ s 107.6 mm (ID)

99.4 mm

8.4 mm <15mA 0.01 ° ± 0.10 ° 360 °

Torque -40C to 150C

-40C to 125C

720°/s(120 rpm)

23 mm (ID) 80 mm (OD)

30 mm 0.20 ° ± 0.20 ° ± 8 °

Torque(using a torsion bar of 1 Nm/°)

-40C to 150C

-40C to 125C

720°/s(120 rpm)

23 mm (ID) 80 mm (OD)

30 mm 0.01 Nm ± 0.20 Nm

± 8Nm

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Non-Magnetic Eddy Current SolutionsCustomizable sensor solution that eliminates magnetic issues by allowing direct position sensing of a metallic target by electromagnetically coupling a coil and a target.

• 150 °C application in the field• High signal dynamics• Low frequency operation (<150 kHz) for the sensor• Dynamic electronic calibration of the target rest/end position with ASIC• Dynamic-analytic self-diagnostics (SIL 2 with 1 coil/1 ASIC)• Variety of signal interfaces • High accuracy and resolution

TouchSensor Field-Effect Patented TechnologyPatented solid-state switch that is software free and replaces the conventional switch. At the field effect technology’s core is the TS10 chip. When 5 V are applied, an electro-static field is created that emanates directly through the protective dielectric substrate senses presense of high-dielectric materials such as fluids, solids, or human tissue.

Liquid level sensing• Discrete switch• Single or multi-level point and position sensing• Methode ASIC available since 2008

Operating Voltage

Operating Temperature

Response Time

Typical Current Consumption

Interface Options

Output configs Packaging Substrate Options

FieldEffect

5 VDC ±10% -40C to 120C 32 µsec 8 µamps DC or matrix

Active high or low

Low-profile 6-Pin SOT 23

Non-conductive materials up to 10 mm thick varying by application

Multispectral Imaging Biometric TechnologyLumidigm’s multi-spectral imaging technology allow fingerprints to be read in real-world conditions such as contaminated surface, dry fingers, wet fingers, dirty fingers, poor ridge expression and interaction effects such as variable placement pressure.

Wake up time

Capture image of finger & generate template

Match template against prior template (Verify)

Match template against prior template database of 100 templates (Identify/Enroll)

Total Time from placing finger to confirmation (last user)

Total Time from placing finger to confirmation (oldest user)

Total time to enroll in system (familiar user, 3 readings)

MethodeLumidignSensor

200 msec 1 sec Less than 1 sec

2 sec Less than 2 sec

Less than 3 sec Approximately20 sec

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Case Studies & ApplicationsUtilized in a wide range of industries and applications around the world, Methode sensor technologies have enabled some of the most critical systems to achieve industry-leading product performance. Through the success of our customers’ products, Methode has become one of the most trusted providers of electromechanical solutions. Read some of our most recent success stories below.

Capacitive Multi-Turn Steering Angle Sensor

ChallengeApproached by a leading sports car manufacturer, Methode was asked to develop a robust absolute multi-turn steering angle sensor (SAS) for a high end sports car manufacturer that would fulfill the demanding requirements of accuracy and resolution. The customer was also looking for additional features such as built-in redundancy, diagnostic and angle information upon “wakeup”. Furthermore, the given available space was challenging and it was not possible to use common available SAS-modules.

SolutionMethode developed a high-resolution, multi-turn, absolute position angle sensor for the vehicle’s Electronic Stability Program (ESP) systems. The product features built-in redundancy and diagnostic communication over serial bus networks, CAN, LIN and more.

StoryMethode’s absolute multi-turn angle sensor measures the steering angle using a three-gear system. The sensing principle is capacitive, which uses relative phase shifts to determine angular displacements between the fixed PCB (emitter and receiver) and the rotating reflectors. It offers a high degree of flexibility in geometrical configurations (packaging size) and operating frequencies (15 kHz – 2 MHz). Velocity can also be used as an optional output. In contrast to previously used SAS systems, Methode‘s innovative capacitive solution does not need any driving magnets or optical arrangements; it’s a single chip sensing solution.

Capacitive Steering Angle Sensor

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Torque, Speed, and Direction Measurement for Light Electric Vehicles

ChallengeApproached by a Light Electric Vehicle (LEV) bike manufacturer, Methode was asked to develop a sensor that would produce a high quality torque measurement, while providing an accurate speed and direction measurement. The challenge was futher complicated by the limited space available to enclose this sensing device in the bracket housing the crankshaft.

SolutionMethode developed a custom sensor that has the capability to measure all three process parameters by incorporating a custom magnetic profile onto the wheel’s crankshaft, allowing the system to measure torque, speed and direction. By accurately measuring the three process parameters, the LEV bike is able to determine how much auxiliary power is needed to assist the rider. The motor automatically switches on or off while responding to the rider’s needs.

StoryPreviously, the market has used a strain gauge mounted on the bike frame that could only measure the indirect applied torque, not actual torque. The strain gauges pick up on deformation of the frame due to the pulling of the chain as the rider applies force to the pedal. Deformation is also caused by impact from uneven surfaces and the weight of the driver, causing false bending measurement in the strain gauges. Additionally, wear on the frame over time causes signal drift leading to further errors in measurement. Calibrating a strain gauge to sense direct torque is impossible as there is no proper reference. There was a need for a clean, direct torque signal that would be accurate and repeatable enabling an on-board motor controller to automatically engage and disengage the rider assist motor.

Methode provided a custom designed sensor that measures torque, speed and direction in a commercially acceptable framework. The sensor performs at a narrowly defined torque range and has the ability of a “three X” torque overload condition without any residual degrading of the sensor. Therefore, as the rider pedals the bike, an absolute torque measurement is made and sent to the control system to engage the electric motor assist when necessary. Because the sensor sends an analog signal, the controller can read changes at the crankshaft at less than 1.0 ms intervals in any road and weather condition. Because the speed sensor does not require a target wheel on the shaft, it can be incorporated within a single package that includes the torque and direction sensing. This is possible even in the limited space available within the lower bracket of a bicycle. This speed signal is then presented in a digital-signal format to the controller for processing. A side benefit of the use of speed in combination with the torque measurement in the control scheme is that the system can provide the rider with horsepower or calorie burn.

E-Bike motor with built-in magnetoelastic torque sensor

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Biometric Fingerprint Sensor

ChallengeLumidigm, a Methode Electronics partner company, was approached to design an automated authentication system for amusement park access. The challenge was to design a system that could help ensure that only one person was using each ticket to gain entry to the park. The solution had to strike the right balance between security and convenience: the ability to prevent ticket sharing was important but only if it could be done without interfering with the positive experience of visitors as they passed through the entry gates. Both conditions had a significant impact on the client’s bottom line.

SolutionMethode was able to meet both requirements with the deployment of multispectral imaging fingerprint sensors. Lumidigm broke new ground developing the multispectral imaging, a technology that enables the measurement of fingerprint characteristics that are at and beneath the surface of the skin. This enhanced data capture mitigates traditional system vulnerabilities and makes Lumidigm sensors the most secure and convenient solution for identity authentication. Multispectral imaging is also outstanding in liveness detection. Multispectral imaging can quickly detect false fingerprint ridges by characterizing the subsurface data against the known characteristics of the human skin. The ability to capture information from both the surface and subsurface of human skin forms the basis of Lumidigm’s distinct competitive advantage.

StoryThe ability to provide convenient, rapid, and hassle-free entry was, and remains, an important part of the visitor experience. But this was just the beginning of a much bigger story. Efficient and reliable user authentication not only provides theme park operators a way of ensuring that ticket holders are legitimate but it opens the door to personalization which enhances the visitor experience even further.

In this way, reliable biometric authentication from Lumidigm has once again turned the “barrier” of personal authentication into an “enabler”. Today Methode Electronics and Lumidigm offer multispectral imaging fingerprint sensors for different areas of access control application such as traveler authentication and border control, vehicle security by driver recognition, fleet management and vehicle monitoring, medical dispensing management and manufacturing process control.

Multi-Spectral Imaging measures the optical properties of the skin to record differentiating characteristics of individuals.

Multi-Spectral Imaging captures information from both the surface and the subsurface of the skin.

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Eddy Current Position Sensor

ChallengeMethode was approached by a leading automotive manufacturer to develop a contactless sensor solution for a clutch pedal application that enhances the quality of the position measurement and adds the ability to sense the clutch pedal position continuously.

SolutionMethode developed a custom sensor based on the eddy current principle. The sensor has the capability to continuously measure the position of the clutch pedal and additionally provides a cruise deactivation signal.

StoryMethode was asked to create a sensor solution that would be incorporated into the control and regulation strategy of different innovative functions resulting in less fuel consumption, more driver comfort and more safety. Previously, the market has used switches to provide the information that the pedal has reached defined end-points of the pedal movement. In those solutions, wear over time causes inaccuracy and malfunction. Furthermore, new functionalities like start-stop-automatic or cruise deactivation require a high accuracy signal over the full range of the pedal movement.

Methode provided a smart and contactless sensor module based on the eddy current principle. The signal is an absolute linear function of the distance between a defined target and the sensor. By means of a convex target surface the rotation of the pedal results in a changing air gap between target (pedal surface) and sensor module. This gives us the ability to measure the whole pedal stroke movement with one single compact sensor device.

The contactless design leads to completely maintenance-free performance, and the compact size makes it very robust.

This position sensing solution achieves a high level of safety and is SIL 2 certified. Built-in intelligence allows continuous monitoring of internal failures and features a patented adaptive end-point-learning algorithm. This sensing solution enables consistent repeatability over product life without any need of recalibration.

Today Methode provides a wide range of custom position sensors for all types of transmission applications such as clutch master-cylinder, double-clutches and in transfer cases.

Clutch pedal position sensor

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LevelGuard® Liquid Level Pump Switch Sensor

ChallengeMethode was asked to develop a more reliable way to prevent basement flooding due to the inaccuracies and failures of the standard float switches commonly used in residential sump pumps.

SolutionMethode’s team designed a sensor switch that uses field-effect technology to monitor fluid levels within residential sump and sewage pits. LevelGuard® is a software free, solid state pump switch that turns your sump or sewage pump on and off. The field-effect technology detects any conductive mass (here water) entering the field and activates the pump evacuating the water from the pit. The field-effect sensor emanates through any dielectric substrate such as glass or plastic. Field-effect touch cells can be easily integrated in any kind of application and are the perfect sensor solution for fluid level control.

StoryDissatisfied with industry standard float switches, homeowners requested a more reliable means of preventing basement flooding. Methode’s design team addressed owners’ concerns and developed the LevelGuard solution. With the market’s first high-current pump control, LevelGuard utilizes patented field-effect sensing technology. Including upper- and lower-level fluid-sensing limits, thermal protection and easy installation mounting features, the solid-state solution met the challenge and surpassed competing float switch alternative 7 to 1 in independent testing.

Field-Effect Touch Cell

The Field-Effect Touch Cell senses the presence of a conductive material such as a finger or water.

LevelGuard™ Pump Switch

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Magnetoelastic Load Pin

Challenge The industrial lift equipment market often uses customized strain gauge solutions for detecting the applied load to avoid any dangerous situations like overloading or flipping. For accurate force and load readings using strain gauges, mechanical changes to the equipment application are required to avoid erroneous force readings. Retrofitting the equipment for accurate readings as well as to comply with legal requirements (e.g. DIN EN ISO 13849-1/EN 14492-2) implies high costs.

Solution Methode developed a modular sensor solution for different areas of applications including force and load measurement on cranes and winches, in vessels and mobile work machines (e.g. tractors, diggers) as well as in reach stackers, forklift trucks, overhead cranes and gantry cranes. This modular solution means no mechanical changes need to be made on the equipment.

The Methode load pin sensor has the capability to measure the load in one or both channels for the x and y component of the applied load. The modularity of the system leads to a high grade of standardization to adapt into many different types of bolts and pins. A robust, modular solution that is highly accurate and repeatable can now be used in various heavy equipment applications.

StoryApproached by a crane and winch manufacturer, Methode was asked to create a sensor solution that measures force and load with high accuracy, while avoiding the downsides of available solutions.

Methode provided a load pin with an integrated magnetoelastic sensor device. Due to the unique ability to measure the load with an x and y channel, the direction of the load can be detected and locating the pin in a fixed position beside the total load is sufficient to achieve an accurate and repeatable measurement. The solution allows easy installation and is feasible for a retrofit strategy.

Methode also incorporated an optional value-add feature: wireless data transmission up to 100m. Due to the low power consumption of the magnetoelastic sensing technology the battery lasts approximately two years. The Methode Load Pin is the most effective way to incorporate a load/force measurement and control system into the application without incurring costly mechanical changes to the heavy equipment.

Loadpin with built-in magnetoelastic shearing force sensor

Who is Methode Electronics?

We are a leading developer of custom-engineered, application-specific products and solutions utilizing ground-breaking technologies.

From biometric identification that utilizes unique characteristics of human skin structure; to magnetic signature sensing of mechanical and electrical properties; to revolutionary solid-state touch sensitive switches used in today’s appliances and

automobiles, Methode’s “Technology Toolbox” brings innovative solutions to our customers’ product needs.

With over 4,000 employees and manufacturing campuses in the Americas, Europe, and Asia, we bring a total business solution to customers worldwide in four key market areas: User Interfaces, Sensor and Switches, Power and Data Solutions.

We are engineers, problem solvers, innovators, forward thinkers, mothers, fathers, and your customer focused partners in business around the globe, that’s why . . .

Methode is possibilities.

Industries We Serve:

• Automotive

• Transportation

• Heavy Industry

• Consumer & Commercial

• Defense & Aerospace

• Alternative & Renewable Energy

• Communications

• Medical

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World Headquarters www.methode.com7401 West Wilson Avenue, Chicago, IL 60706Phone: (708) 867-6777 | Fax: (708) 867-6999

Methode MaltaMriehel Industrial Estate, Mriehel BKR 3000, MaltaPhone: +356-2148-4184 | Fax: +356-2144-6679