IN Brief:
- TDK has introduced the HAL 3025 Micronas Hall-effect sensor for high-speed position sensing.
- The device targets EV traction motors, steer-by-wire, brake-by-wire, and industrial drives.
- ASIL D readiness and stray-field immunity address tougher safety and integration requirements in motion-control systems.
TDK has launched the HAL 3025 Micronas Hall-effect sensor for motor position sensing in electric vehicle traction motors, steer-by-wire systems, brake-by-wire systems, and industrial drives.
The device measures full 360-degree rotational position using TDK-Micronas’ SixSense technology, which evaluates the vertical magnetic field component while suppressing external DC and AC magnetic stray fields. It provides analogue sine and cosine outputs, allowing engineers to integrate the sensor into established motor-control architectures.
Designed for high-speed applications, the HAL 3025 supports rotational speeds up to 60,000rpm and is intended for use with a simple two-pole ferrite magnet. That combination gives designers a route to robust position sensing without relying on more complex magnetic assemblies where cost, packaging, and assembly tolerance can become limiting factors.
The sensor has been assessed for ISO 26262 ASIL D requirements and includes diagnostic functions for safety-critical systems. It is supplied in an SOIC8 package and supports operation from -40°C to 170°C, making it suitable for environments close to motors, inverters, and power electronics.
Magnetic sensing in drive systems has become more demanding as electric powertrains and compact industrial actuators place current conductors, switching devices, and sensing elements closer together. The resulting magnetic noise can make conventional position sensing less predictable, particularly when systems are expected to maintain accuracy under high load, high temperature, and strong electromagnetic interference.
Drive-by-wire platforms add another layer of design pressure. Steering and braking systems rely on redundant sensing, diagnostics, and safe operating states, with position feedback tied directly to functional safety evidence. Industrial automation is moving in the same direction as autonomous mobile robots, compact servos, and high-speed machinery require position feedback that remains stable under vibration, electrical noise, and thermal cycling.
Analogue sine and cosine outputs keep the device compatible with familiar motor-control signal chains. While digital sensor interfaces are expanding across many applications, analogue outputs remain useful where designers want deterministic behaviour, low-latency signal processing, or a clearer migration path from resolver-style architectures.
The arrival of HAL 3025 reflects a wider shift in motion-control electronics. Sensors are now judged not only by resolution and cost, but also by their tolerance to stray fields, package performance, diagnostic coverage, and functional safety documentation. As motors and power electronics become more tightly integrated, position sensing has moved from a peripheral component choice to a core part of system reliability.
Samples of HAL 3025 are available now, with production planned for the second quarter of 2026. Its combination of high-speed operation, ASIL D readiness, and stray-field robustness places it firmly in the next generation of EV and industrial drive designs.
