IEEE SENSORS JOURNAL, VOL. 15, NO.
7, JULY 2015
An Inductive Angular Displacement Sensor Based
on Planar Coil and Contrate Rotor
Qifu Tang, Donglin Peng, Liang Wu, and Xihou Chen
Abstract— This paper introduces a noncontact, low-cost, and
reliable inductive sensor for angular displacement measurement.
It is suitable to work in harsh industrial environments.
The sensor has simple structure consisting of three key
parts: 1) a ferromagnetic stator, which is a pure plane;
2) a ferromagnetic rotor, which has face slots; and 3) four
layers of planar copper coils, including primary and secondary
coils. Primary coils are supplied with two orthogonal 4000-Hz ac,
and secondary coils output a signal whose phase is proportional
to angular displacement. Primary coils are designed with
sinusoidal shape, so that magnetic field between the stator
and rotor has approximately sinusoidal distribution, and
finally linearity between the phase variation of output signal and
angular displacement is well helped by this design. The structure
and working principles of the sensor are explained in detail.
Moreover, a sensor model was simulated to verify the feasibility
of the sensor working principles and a sensor prototype was
designed for actual experiment. At last actual experiment results
are given and analyzed, showing that the sensor prototype
has achieved accuracy better than ±12 arcsec in the range of
0°–360°, and this kind of sensor may have a better performance
by improving the layout of primary coils and front-end
signal-process circuit.
Index Terms— Non-contact inductive sensor, angular
displacement, planar coils, contrate rotor, sinusoidal shape.
I. I NTRODUCTION
T HERE are various sensors for angular displacement mea-
surement, such as optical encoders that can realize high
resolution and accuracy [1], [2], microwave-based devices
that have high sensitivity, resolution and the advantage of
miniaturization [3]–[5], capacitive sensors that also have high
sensitivity and resolution [6], and inductive sensors that have
strengths in applications for rough industrial conditions [7].
Though inductive sensors don’t have superiority in sensitivity,
Manuscript received November 26, 2014; revised January 11, 2015;
accepted February 11, 2015. Date of publication February 16, 2015; date
of current version May 19, 2015. This work was supported in part by
the National High Technology Research and Development Program (863
Program) of China under Grant 2012AA041202, in part by the National
Natural Science Foundation of China under Grant 51127001, and in part by
the Major National Scientific Instrument and Equipment Development Project
under Grand 2013YQ220893. The associate editor coordinating the review of
this paper and approving it for publication was Prof. Zeynep Celik-Butler.
(Corresponding author: Donglin Peng.)
Q. Tang is with the State Key Laboratory of Mechanical Transmission,
Chongqing University, Chongqing 400044, China (e-mail: sealyl@126.com).
D. Peng, L. Wu, and X. Chen are with the Engineering Research Center
of Mechanical Testing Technology and Equipment, Ministry of Education,
Chongqing University of Technology, Chongqing 400054, China (e-mail:
pdl@cqut.edu.cn; wh0219@cqut.edu.cn; cxh0458@cqut.edu.cn).
Color versions of one or more of the figures in this paper are available
online at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/JSEN.2015.2404349
1530-437X © 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
3947
resolution, accuracy or miniaturization, they have superior
performance and hence are widely used in harsh working
environments [7]–[14], for that inductive techniques are less
affected by undesired matter like water, dust, or oil, and
usually use symmetrical structure to cancel electromagnetic
noise [15], [16]. Recent inductive sensors trend to use printed
circuit board (PCB) [17] or other technologies [18], [19] to
lower sensor cost, improve compactness, etc. References [15],
[20], and [21] introduce three types of inductive sensors, an
absolute linear position sensor, an absolute angular position
sensor and an incremental angle sensor, which are all based
on PCB technology. PCB technology has a strength that it
can easily control coil layout to meet special requirement that
traditional coil-making technology can’t. The planar angular
displacement sensor presented in this paper also works on
inductive techniques and it utilizes a PCB to make coils of
which primary coils have sinusoidal shape. Besides common
advantages inductive sensors have, this sensor has other advan-
tages compared with traditional angular displacement sensors,
e.g., resolvers and round inductosyns. Resolvers have trouble
to make uniform coils, especially complex coils to overcome
harmonics [22]–[24] introduced by sensor mechanical struc-
ture or unsymmetrical coils or excitations. Though inductosyns
have no trouble like resolvers, they have very weak output
voltage [25], [26] which is even in microvolt scale, as a result
electrical part has heavy work to get smooth signals from sen-
sor output signals. Relatively, this paper presents a new sensor
structure which can avoid disadvantages that exist in resolvers
and inductosyns. The sensor integrates primary and secondary
coils into a single PCB which can offer fairly uniform repeated
coil cells compared with resolvers. Moreover, primary coils
are designed with sinusoidal shape in order to get magnetic
field with sinusoidal distribution between the stator and rotor.
What’s more, the sensor employs a ferromagnetic stator as
the base plane to fix the PCB and meanwhile help enhance
magnetic field density and form sinusoidal distribution.
Following section I, section II introduces the sensor
structure and working principles in detail. Section III
introduces the simulation of a sensor model. Section IV
introduces the experiment of a sensor prototype and according
results. At last, conclusions are summarized and discussed
in section V.
II. S TRUCTURE AND M EASUREMENT P RINCIPLES
A. Structure of the Sensor
As shown in Fig.1, the sensor mainly consists of three
components, including a stator, a rotor and four layers of
3948
Fig. 1. Structure diagram of the angular displacement sensor. (a) Overall view. (b) Exploded view.
Fig. 2. The magnetic field between the stator and rotor.
copper coils. The stator is a pure plane while the rotor has
slots evenly divided in its face. They are both made of the
same ferromagnetic material steel_1010. All coils are placed
between the stator and rotor, and they keep stationary as well
as the stator when making measurement. Primary coils have
four circles, named coil C1, C2, C3 and C4 in Fig. 1. They are
all designed with sinusoidal shape, and in space there is 1/4 of
the sinusoidal period difference between adjacent circles. The
number of sinusoidal periods in each circle of primary coil
is equal to the number of slots in the rotor. C1 and C2 have
the same wound direction but different from C3 and C4. C1
and C3 are supplied with the excitation of alternating current
(AC) which has 90° phase difference from the excitation for
C2 and C4. Secondary coils are theoretically in the same
plane as primary ones, including inner and outer circles of
coils. Inner and outer secondary coils have different wound
directions.
B. Measurement Principles of the Sensor
Like other phase-detect-based angular sensors, this sensor is
designed to produce a sinusoidal signal whose phase is propor-
tional to the angular displacement. Coils C1 and C3 are driven
by the excitation ea (t) = Asin(ωt), while coils C2 and C4
are driven by the excitation eb (t) = Acos(ωt). When only
ea (t) works in the sensor, the magnetic field between the stator
IEEE SENSORS JOURNAL, VOL. 15, NO. 7, JULY 2015
and rotor will have a distribution as Fig.2 shows. Because the
rotor is made of ferromagnetic material, the magnetic density
of the area covered by rotor tooth, BT , is greater than B S ,
that of the area covered by rotor slot. Taking the shape of
C1 and C3 into consideration, the magnetic flux φa (t, θ ) in
secondary coils coming from the excitation ea (t) is calculated
by Eq. (1).
⎛ ⎞
θ+π / N
θ 2h B T h sin(Nθ )dθ
φa (t, θ ) = N ⎝  ⎠ (1)
θ+2π N
+ θ+π / N/ 2h B S h sin(Nθ )dθ
where N is the number of sinusoidal periods in each circle of
primary coil, θ is the angular displacement, h is the radius of
middle line of primary sinusoidal coils, h is the amplitude
of the sinusoidal coils.
Together with ea (t), Eq. (1) can be expressed as
4 Ahh sin(ωt) · cos(Nθ ) · (R S − RT )
φa (t, θ ) = (2)
r a RT R S
where ra is the AC impedance of C1 and C3, RT and R S are
the reluctance between the stator and rotor where there is a
rotor tooth and a rotor slot respectively.
According to the Faraday’s law, the electromotive
force (EMF) ea (t, θ ) of secondary coils induced singly from
the magnetic field generated by C1 and C2 is expressed
TANG et al.: INDUCTIVE ANGULAR DISPLACEMENT SENSOR BASED ON PLANAR COIL AND CONTRATE ROTOR 3949

Fig. 3. Diagram of processing circuit for output signal of the sensor and angle information obtaining method based on the sensor signal and reference signal.

as Eq. (3). Using Eq. (2) and (3), ea (t, θ ) can be written  (t,θ ), the method employed for this sensor is to
signal eab
as Eq. (4). make comparison between eab  (t,θ ) and a reference signal.

dφa (t, θ ) The comparison is carried out using digital rather than analog
ea (t, θ ) = (3)  (t,θ ) is an analog signal, so firstly it is transformed
signals. eab
dt
4ω Ahh cos(ωt) · cos(Nθ ) · (R S − RT ) to a square signal, named Sm , by the weak signal conditioning
ea (t, θ ) = (4) and zero-cross detecting circuit, then Sm is compared with the
r a RT R S
reference signal Sr as shown in Fig.3. Sr is also a square signal
Likewise, when only one excitation eb (t) works in the and it has the same period T as excitations ea (t) and eb (t).
sensor, the magnetic flux φb (t, θ ) in secondary coils can The comparison between Sm and Sr is actually to count time
be calculated similarly as Eq. (1). However, φb (t, θ ) has from rising edge of Sr to that of Sm . The time interval
90° phase difference from φa (t, θ ) in θ because of the 1/4 of t varies with the rotation of rotor and has a relation with θ
the sinusoidal period difference between adjacent primary as shown by Eq. (9).
circles, therefore φb (t, θ ) is expressed as  
⎛ ⎞ n t
θ+3π / 2N θ = 2π + (0 ≤ n < N) (9)
θ+π / 2N 2h BT h sin(Nθ )dθ N T
φb (t, θ ) = N ⎝  ⎠ (5)
θ+5π 2N
+ θ+3π //2N 2h B S h sin(Nθ )dθ where n is the number of T that Sm travels relative to Sr .
Together with eb (t), Eq. (5) and EMF eb (t, θ ) of secondary
III. S IMULATION OF THE S ENSOR M ODEL
coils induced singly from the magnetic field generated
by C2 and C4 can be expressed as A simulation model of the sensor was designed in magnetic
4 Ahh cos(ωt) · sin(Nθ ) · (R S − RT ) finite element analysis (FEA) software Ansoft Maxwell 12.1
φb (t, θ ) = − (6) and its structure is the same as Fig.1 shows. Primary coils
r b RT R S have 24 sinusoidal periods in a circle, the rotor accordingly has
4ω Ahh sin(ωt) · sin(Nθ ) · (R S − RT )
eb (t, θ ) = (7) 24 slots. The radius of middle line of primary sinusoidal coils
r b RT R S is 41mm and the amplitude of these sinusoidal coils is 4mm.
where rb is the AC impedance of C2 and C4, it is equal to ra . Radiuses of middle lines of inner and outer secondary coils
Therefore, when excitations ea (t) and eb (t) both work are 32.5mm and 50mm. Two excitations for primary coils,
in the sensor, the magnetic flux in secondary coils is the ea (t) and eb (t), have the frequency of 4000Hz and amplitude
superposition of φa (t, θ ) and φb (t, θ ), and then total EMF of 5V. Material of all coils is set to copper. Material of stator
is the sum of ea (t, θ ) and eb (t, θ ), written as Eq. (8). and rotor is set to steel_1010. The distance between stator and
 rotor is set to 1mm. Inner and outer radiuses of stator and rotor
eab (t, θ ) = ea (t, θ ) + eb (t, θ )
are 30mm and 60mm respectively. Rotor slot depth is 2.8mm.
4ω Ahh · (R S − RT ) · cos(ωt − Nθ )
= (8) To reduce calculation time, thicknesses of stator and rotor are
r a RT R S set to only 0.5mm and 5mm. However, sizes mentioned above
From Eq. (8), it is concluded that eab (t,θ ) is a time- of the sensor model are not strict very much, because this
varying sinusoidal signal whose phase is proportional to model aims to obtain the more accurate relation between EMF
the angular displacement. To obtain angle information from of secondary coils and angular displacement qualitatively,
3950 IEEE SENSORS JOURNAL, VOL. 15, NO. 7, JULY 2015

Fig. 4. EMF of secondary coils under different working conditions of two excitations when rotor makes 15° rotation with a step of 0.5°; different curves
in (a), (b) and (d) represent secondary EMFs of different positions of the rotor. (a) Secondary EMF when ea (t) is effective only. (b) Secondary EMF when
eb (t) is effective only. (c) Contrast between theoretical and actual amplitude variation of EMFs in (a) and (b). (d) ea (t) and eb (t) are both effective.

Fig. 5. Variation of phase (θ  ) of secondary EMF eab

 (t, θ ) with the rotation of rotor, where θ  = 24θ .


i.e. eab (t, θ ) and θ , than simple mathematical analysis.
According to measurement principles of the sensor, when there
is only one excitation working, EMF of secondary coils has
the forms as Eq. (4) and (7) indicate. In the simulation of this
sensor model, two excitations are set singly and as a result
of 15° rotation of rotor with a step of 0.5°, there are output
EMF curves of secondary coils as shown in Fig.4 (a) and (b).
Theoretically when the rotor rotates, the amplitude of sec-
ondary EMF under single excitation should vary following a
sinusoidal curve, therefore amplitude variations of secondary
TANG et al.: INDUCTIVE ANGULAR DISPLACEMENT SENSOR BASED ON PLANAR COIL AND CONTRATE ROTOR
Fig. 6. Density and distribution of magnetic field when stator is set to non-ferromagnetic and ferromagnetic material, respectively. (a) Stator material is set
to vacuum. (b) Stator material is set to steel_1010.
EMF curves of Fig.4 (a) and (b) are extracted and given
in Fig.4 (c), named actual curves, while standard sinusoidal
curves corresponding to two actual curves are also given,
named theoretical curves. It should be noted that theoretical
curves are added a +2mV offset deliberately for clear identi-
fication from actual curves because actual curves are close to
theoretical ones. The deviations shown in Fig.4 (c) of actual
curves from theoretical ones can cause nonlinearity from
t to θ in Eq. (9), but this kind of deviation may be reduced
easily by adjusting the shape of primary coil of a given sensor.
However, here this paper won’t introduce the detail about
adjusting primary coil shape. When two excitations are both
set to be effective, the output EMF curves of secondary coils
with the same rotation of rotor are shown as Fig.4 (d) where
curves have nearly identical amplitude but different phase.
If the phase of secondary EMF eab  (t, θ ) is expressed with
  
θ , then θ has the relation θ = 24θ with θ according to
Eq. (8) and the number of sinusoidal periods in each circle of
 (t, θ ) varies for 24 periods as
primary coil. In other words, eab
θ varies from 0° to 360°. Fig.5 shows that θ  keeps almost
constant as rotor rotates with a constant step, thus t, gained
by processing secondary EMF using the method illustrated in
Fig.3, can have good linearity with θ.
Though the sensor has a lot of parameters that can affect
the relation between EMF of secondary coils and angular
displacement, such as rotor slot depth, distance between stator
and rotor, distance between primary and secondary coils, it
needs to be emphasized that the material of stator is a key
factor to the sensor. The stator, if made of ferromagnetic
material, not only can enhance the magnetic field received
by secondary coils, but also can improve the distribution
of magnetic field between stator and rotor. That is because
ferromagnetic stator attracts more magnetic filed generated by
primary coils to transmit in the direction vertical to stator
plane and meanwhile reduces reluctance of closed path of
the magnetic field. Contrast simulations were made and the
density and distributions of magnetic field in two simulations
3951
are shown as Fig.6. When stator is set to steel_1010, magnetic
field has higher density and area-bigger distribution than that
when stator is set to vacuum. The distribution of magnetic
field has clearer space periods along the sensor.
IV. E XPERIMENT AND R ESULTS
A sensor prototype was designed according to the simula-
tion model, as shown in Fig.7 (a). Primary and secondary coils
are made in an annular PCB whose thickness is about 0.8mm.
The stator has a 0.8mm-thick countersink to install the PCB
and 6 pylomes to allow it to be mounted on the marble frame
of the experiment platform. Key dimensions of the sensor
prototype are given in Fig.7 (a). The rotor has the nearly same
structure to that shown in Fig.1, but it is different from the
configuration in Fig.1 that the rotor is configured above the
stator in the experiment due to the platform structure. Fig.7 (b)
shows the overall view of the experiment. The marble frame
is used to install a motor, a rotary table, an angle encoder
and the sensor prototype. An industrial computer is equipped
for the motor servo system and data acquisition (DAQ). The
circuits for the sensor were integrated into a box in order
to keep reliable connections. The rotary shaft for connecting
sensor rotor is coaxial to the shaft that connects the angle
encoder which is used to examine and correct the sensor.
The sensor and angle encoder are driven by the rotary table
in the experiment platform. Position data of the sensor and
angle encoder are synchronously acquired by the circuit and
then transmitted to the computer via a RS232 port.
The error of the sensor has been tested before and after
correction respectively in the range of 0° to 360°, and
test results are shown in Fig.8. The experiment adopts
HEIDENHAIN RON886 angle encoder which has 1 arcsec
accuracy to perform examination and correction for the sensor.
Before correction, as shown in Fig.8 (a) and (b), test results
indicate that the sensor has very regular error. From 0° to 360°,
the error varies 24 times obviously because primary coils
have 24 sinusoidal periods, and in the range of 0° to 15°
3952 IEEE SENSORS JOURNAL, VOL. 15, NO. 7, JULY 2015

Fig. 7. Configuration of the sensor prototype and pictures of experiment. (a) Configuration of the sensor prototype. (b) Overall view of experiment.

Fig. 8. Error of the sensor compared with HEIDENHAIN RON886 angle encoder: (a) original error in (0°-360°); (b) original error in one period
(0°-15°); and (c) error after correction.

the sensor mainly has first- and second-order error. Therefore,
the sensor can be corrected easily. After correction, as shown
in Fig.8 (c), test result indicates that the sensor achieves
accuracy of less than 12 arcsec in the full range.
V. C ONCLUSION
The structure of a non-contact inductive angular
displacement sensor is described and its working principle
is verified feasible by theoretical analysis, model simulation
and actual experiment. The sensor takes use of planar
sinusoidal-shape primary coils to generate magnetic field
which has sinusoidal distribution between the stator and rotor.
It was proved by the simulation that this sinusoidal layout
offers good linearity between the phase of output signal and
angular displacement. However, because of the asymmetric
layout of primary coils in PCB, the experiment shows that the
sensor prototype has big original error. According to the error
regularity, this kind of error may be reduced by reorganizing
TANG et al.: INDUCTIVE ANGULAR DISPLACEMENT SENSOR BASED ON PLANAR COIL AND CONTRATE ROTOR
layout of the PCB or using other coil-making technologies.
In this sensor prototype, primary coils are in different layers
of the PCB and they are connected with pads in different
paths, so this subtle difference causes asymmetric coil layouts
and unequal coil impedances, and then first- and second-order
errors are brought in. Plus, first- and second-order errors
are main errors of the sensor. As a result, it is possibly
an effective way to reduce this kind of error by improving
the layouts of primary and secondary coils or using other
technologies to realize relatively symmetrical coil layouts
and equal coil impedances. For example, inner and outer
secondary coils have different radiuses but same turns, so
asymmetric layout of primary coils causes different influences
on inner and outer secondary coils. To reduce this difference,
it is a solution to increase turns of inner secondary coils
or decrease turns of outer secondary coils appropriately.
In addition, decreasing the amplitude and increasing turns
of primary coils can help to lower asymmetry, because the
ratio of asymmetric turns which need connection with pads
to symmetric ones goes down.
What’s more, the front-end circuit used in the experiment
has not been redesigned specially for this kind of sensor,
so much noise mixed in secondary EMF influences the
repeatability of the sensor. To achieve higher accuracy after
correction, circuit improvement is also being carried out in
following research.
Even though the senor prototype hasn’t worked in
good condition, it has ±12 arcsec accuracy in the range
of 0° to 360°. In addition, the sensor has very simple structure
and its components don’t require complex fabrication, thus this
kind of inductive angular displacement sensor may have good
use in many industrial applications.
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Qifu Tang received the M.Eng. degree in
measurement and instrumentation from the
Chongqing University of Technology, Chongqing,
China, in 2012. He is currently pursuing the Ph.D.
degree at the State Key Laboratory of Mechanical
Transmission, Chongqing University, with a
focus on precision measurement technologies and
instruments of displacement.
Donglin Peng received the M.Eng. and Ph.D. (Eng.)
degrees from Chongqing University, in 1988 and
1992, respectively. He was with the State Key
Laboratory of Mechanical Transmission, Chongqing
University, from 1982 to 2000. Since 2000, he has
been with the Chongqing University of Technology.
His research interests include precision measurement
technologies and instruments.
3954
Liang Wu received the B.Eng. and M.Eng. degrees
in measurement and instrumentation from the
Chongqing University of Technology, Chongqing,
China, in 2008 and 2011, respectively. He is
currently pursuing the Ph.D. degree at Chongqing
University. Since 2012, he has been a Research
Assistant with the Engineering Research Center
of Mechanical Testing Technology and Equipment,
Ministry of Education, Chongqing University of
Technology. His research interests are modeling and
simulation of sensors for displacement measurement.
IEEE SENSORS JOURNAL, VOL. 15, NO. 7, JULY 2015
Xihou Chen received the M.Eng. and
Ph.D. (Eng.) degrees from Chongqing University, in
2004 and 2007, respectively. Since 2007, he has been
a Professor with the Chongqing University of
Technology. He mainly focuses on the research of
displacement sensors and technologies of precision
mechanical measurement.