S E N S O R S

G L O B A L A U T O M O T I V E D I V I S I O N

2

3

Tyco Electronics is one of the major business units of Tyco International Ltd. Headquartered in

Harrisburg, Pennsylvania, USA,Tyco Electronics is the world’s largest passive electronic components

manufacturer and a world leader in cutting-edge wireless technologies.The company has facilities

located in over 50 countries, serving customers in the aerospace, automotive, computer,

communications, consumer electronics, industrial and power industries.

G L O B A L A U T O M O T I V E D I V I S I O N- S E N S O R T E C H N O L O G Y

Non-contact measuring eliminates interference effects, wear and tear, and provides

increased reliability. Tyco Electronics, one of the largest technology providers for the

automobile industry, offers non-contact sensors for a variety of applications.As sensor

manufacturer and processing partner, Tyco Electronics also provides project planning

support for new sensor applications, assistance in the selection of the appropriate

sensor technology for the respective application, and assistance with defining the

corresponding mechanical, electrical and magnetic interface.Tyco Electronics has a broad

electromechanical portfolio that includes robust housing technologies, connector

systems, and temperature stable designs based on foil and cable networks.

This combination of technologies and experience ensures that reliable and cost effective

sensor solutions are available for all application types.

A V I T A L P A R T O F Y O U R W O R L DTyco businesses operate in thousands of different areas of industry.The products and services we

deliver all have one thing in common.They are vital to everyday living. Individuals and companies

worldwide have critical needs.And every minute of every day, we satisfy them.

4

U-magnet concept for magnetically biased sensors

PLCD sensor element for non-contact travel and

angualr measurement

S E M I - C O N D U C T O R S E M I - C O N D U C T O R M A G N E T O -A P P L I C AT I O N R E Q U I R E M E N T S S E N S O R S S E N S O R S I N D U C T I V E

H A L L E F F E C T M R E F F E C T P L C D S E N S O R S

T R A V E L M E A S U R E M E N T

Operating range < 15 mm

Operating range > 15 mm

A N G L E M E A S U R E M E N T

Tangential, opreating range < 90˚

Axial, operating range > 90˚

S P E E D M E A S U R E M E N T

I N T E G R AT I O N R E Q U I R E M E N T S

Small Space

Large Operating range position tolerance

Large control distances (through structure walls)

R O B U S T N E S S

High-precision performance with Mechanical load e.g.Vibration

High-precision performance with high ambient temperature

5

T E C H N O L O G Y

Tyco Electronics has focused on non-contact sensors solutions special for high performing and

sophisticated measurement tasks. Wear influences as well as mechanical interactions between

sensor and application parts are then avoided. Beside the actual measurement requirements, the

application conditions determine the choice of the appropriate sensor technology. For non-contact

measurements preferably magnetic sensor technologies are used:

• Semi-conductor sensors with integrated Hall

• Semi-conductor sensors with MR elements

• Magneto-inductive PLCD sensors

• Temperature sensor devices

Table (p.4) compares the characteristic application profile of these important sensor

technologies. Semi-conductor solutions with Hall and MR effect show their advantages

in their very compact and slim design.They are also preferred in the design of complex

sensor clusters. The combination with different magnet configurations, typical integrated

or moving magnets obtains precise measurement results.

A very efficient and robust sensor technology is the Tyco Electronics patented PLCD

(Permanentmagnetic Linear Contactless Displacement Sensor) Technology. For the

linear position measurements this principle has various advantages. The magnetic-

inductive measuring principle distinguishes for its very large operation tolerance field.

This enables the renunciation for specially guided or stored slider and records reliably

its highly precise measuring performance without any loss, not being influenced by

metal abrasions.The necessary driving magnet can herewith be fixed directly on the

setting element, whereas even driving distances through non-ferromagnetic walls with

several millimetre thickness, are not an exclusion criteria for this measuring principle.

A fully enclosed design guarantees the robustness of this measuring principle.

Therefore the encapsulated sensor is completely sealed and temperature resistant up

to 160°C.

A U T O M O T I V A T E D I N E V E R Y D E T A I LOur global automotive research centers are setting the technological landscape by developing

new technologies, products and production processes. The increasingly fast growing number of

functions in present and future cars require varieties of powerful and versatile connection

systems. We compare existing standards with alternative possibilities in which costs, functionality,

dependability and serial production are the basics of our procedures.

Door Locking Unit with integratedHall-Devices

PLCD Gear & Shift travel sensor forAutomated Manual Transmission

6

Digital and linear position measurement for clutch

master cylinder

PLCD sensor module for gear and shift measurement

7

C O M P E T E N C E S

Tyco Electronics, as sensor manufacturer and development partner, utilizes its experience to

provide customer support on project work of new sensor applications. Once the application has

been analyzed, the suitable sensor technology is selected and the corresponding mechanical,

electrical and magnetic interfaces are defined.

The design of the magnetic interface in particular requires a close cooperation with the customer.

Special attention is paid to the external influencing factors of the applications.

During the design of the magnetic circuits, analytical and empirical

methods are used which take into account the magnetic polarization

angle-error and the surrounding magnet field influences. State-of-the-art

procedures, involving FEM calculations, are used to analyse or design

magnetic circuits. Based on the results of these calculations, the

properties of the magnet arrangement will be verified and optimised

through prototype testing.

Specific integrated electronic units ensure reliable signal conditioning and implementation of

additional functions such as advanced signal evaluations, generation of control signals and

complex diagnostic features.The electronic functions are designed with efficient ASIC technologies.

The selection of materials is determined by technical constructive requirements as well as on the

environmental conditions. The wide temperature-load profile, high vibration strains and many

different chemical liquids define the requirements regarding robustness and sealing of the

respective sensor technology. The product architecture is defined by the application space

requirements and the required connector or pigtail requirements. For hermetic and oil-tight

sealing the sensor housings are molded without blowholes and closed with laser-welded housing

covers.

Extensive component tests and life tests under application conditions provide the proof for a

reliable and durable sensor design.

P R O J E C T P L A N N I N G A N D A S S I S TA N C EAs sensor manufacturer and processing partner, Tyco Electronics also provides project planning

support for new sensor applications, assistance in the selection of the appropriate sensor

technology for the respective application, and assistance with defining the corresponding

mechanical, electrical and magnetic interface.

FEM calculation for dimensioning the magnetic sensor interface

A P P L I C A T I O N S

Tyco Electronics offers a comprehensive portfolio of sensors for the automotive industry,

including switching, travel, rotational, speed and temperature. The primary focus is on non-

contact technologies to ensure a high level measuring performance, longterm reliability, and the

elimination of interference effects and wear and tear.

Tyco Electronics is the leading supplier for non-contact sensors for hydraulic, pneumatic and

electro-mechanical actuators used on cars, trucks and busses.

Typical applications are:

• Automated Transmission and Clutch Systems

• Turbocharger, Throttle, Exhaust Gas Recirculation (EGR), Manifold Intake

• Generator, Alternator

• Electrical Powered Assisted Steering (EPAS)

• Convertibles

In addition to the controlled actuator segment, Tyco Electronics also offers a wide range of

innovative and cost-effective sensor solutions for following applications:

• Seat sensors (track position, occupant weight, buckle)

• Clutch- and Brake pedal switches

• ABS wheel speed

• Cam- and Crankshaft

• Transmission gear wheels

• Chassis level

• Door- and tailgate latches

• Outer air temperature

• Fuel level

8

R E L A T E D T E C H N O L O G I E S

MECHATRONICSINDUCTIVESYSTEMS

TERMINALS &CONNECTORS

9

O T H E R T Y C O E L E C T R O N I C S A U T O M O T I V E T E C H N O L O G I E S

CLOCKSPRINGS HIGH SPEEDCOMMUNICATION

POWER DISTRIBUTIONSYSTEMS

RELAYS &SWITCHING MODULES

WIRELESS

Non-contact and redundant brakelight switch (integrated magnet)

PLCD travel sensor forhydraulic cylinder

Integrated PLCD travel sensor for pneumatic cylinder

Non-contact throttleposition sensor

Seat track position sensor(integrated magnet)

10

T Y C O E L E C T R O N I C S “ A T Y O U R S E R V I C E ”

Internet Homepagewww.tycoelectronics.com

www.tycoelectronics.com/automotive

Electronic InternetCatalogwww.catalog.tycoelectronics.com

Electronics OnlineThe Tyco Electronics Website is more than

merely an Internet-guide. It is an innovative

and inter-active source for application tips,

product update and technical information.

With our StepSearch-Software you can easily

surf through all of our product lines.

Product InformationCenter (PIC)You can rely on our PIC Team’s support. Our

experienced staff is an additional information

source, and the team has been particularly

trained to answer your technical questions.

To reach our PIC, please contact your local

Tyco Electronics organization.

Product and MachineLiteratureFor more information about Tyco Electronics’

Global Automotive Division and its wide

range of products we offer you a variety of

literature such as product databooks and a lot

of product specific brochures. For databooks

and product brochures please contact your

local Tyco Electronics organization.

11

Argentina – Buenos AiresPhone: +54-1-733-2000 Fax: +54-1-717-0988

Brasil – São PauloPhone: +55-11-2103-6000 Fax: +55-11-2103-6200

Canada – TorontoPhone: +905-475-6222Fax: +905-474-5520

Chile – Santiago Phone: +56-2-739-1230 Fax: +56-2-739-1227

Colombia – Bogota Phone: +57-1-231-9398 Fax: +57-1-240-3769

Mexico – Mexico CityPhone: +52-5-729-0400Fax: +52-5-361-8545

United StatesHarrisburg, PA Phone: +1-717-564-0100 Fax: +1-717-986-7575

Troy, MIPhone: +1-248-273-3359 Fax: +1-248-273-3322

Customer Service:Phone: +1-800-522-6752

Venezuela – Caracas Phone: +58-2-986-7774 Fax: +58-2-986-9739

For Latin/South AmericanCountries not shownPhone: +54-11-4733-2015Fax: +54-11-4733-2083

Australia – Sydney Phone: +61-2-9554-2600 Fax: +61-2-9502-2556

India – Bangalore Phone: +91-80-2854-0800 Fax: +91-80-2854-0820

Indonesia – Jakarta Phone: +62-21-526-7852 Fax: +62-21-526-7856

Japan – Kawasaki, KanagawaPhone: +81-44-844-8111Fax: +81-44-812-3207

Korea – Seoul Phone: +82-2-3415-4500 Fax: +82-2-3486-3810

Malaysia – Selangor Phone: +60-3-7805-3055 Fax: +60-3-7805-3066

New Zealand – Auckland Phone: +64-9-634-4580 Fax: +64-9-634-4586

Philippines – Makati City Phone: +632-867-8641 Fax: +632-867-8661

People’s Republic of ChinaHong Kong Phone: +852-2735-1628 Fax: +852-2735-0243

ShanghaiPhone: +86-21-6485-7333 Fax: +86-21-6485-6222

Singapore – Singapore Phone: +65-480-4525 Fax: +65-482-1012

Taiwan – Taipei Phone: +886-2-2664-9977 Fax: +886-2-2664-9900

Thailand – Bangkok Phone: +66-2-955-0500Fax: +66-2-955-0505

Vietnam – Ho Chi Minh CityPhone: +84-8-930-4547Fax: +84-8-930-3443

Austria – Vienna Phone: +43-1-905-60-0 Fax: +43-1-905-60-1333 Product Information Center:Phone: +43-1-905-60-1249 Fax: +43-1-905-60-1251

Belgium – Kessel-Lo Phone: +32-16-352-300 Fax: +32-16-352-352

Bulgaria – Sofia Phone: +359-2-971-2152 Fax: +359-2-971-2153

Czech Republic – Kurim Phone: +420-5-41-162-111 Fax: +420-5-41-162-223 Product Information Center:Phone: +420-5-41-162-113 Fax: +420-5-41-162-132

Denmark – Glostrup Phone: +45-43-480-400 Fax: +45-43-441-414

Egypt – Cairo Phone: +20-2-417-76-47 Fax: +20-2-419-23-34

Finland – Helsinki Phone: +358-95-12-34-20 Fax: +358-95-12-34-250

France – Cergy-Pontoise Cedex Phone: +33-1-3420-8888 Fax: +33-1-3420-8600Product Information Center:Phone: +33-1-3420-8686 Fax: +33-1-3420-8623

France Export Divisions –Cergy-Pontoise Cedex Phone: +33-1-3420-8866 Fax: +33-1-3420-8300

Germany – Bensheim Phone: +49-6251-133-0 Fax: +49-6251-133-1600Product Information Center:Phone: +49-6251-133-1999 Fax: +49-6251-133-1988

Great Britain – StanmoreMiddlesex Phone: +44-8706-080-208 Fax: +44-208-954-6234Product Information Center:Freephone GB: 0800-267-666Phone: +44-208-420-8341

+44-208-420-8343Fax: +44-208-420-8081

Greece – Athens Phone: +30-210-9370-396/397Fax: +30-210-9370-655

Hungary – Budapest Phone: +36-1-289-1000 Fax: +36-1-289-1010Product Information Center:Phone: +36-1-289-1016 Fax: +36-1-289-1017

Ireland – Dublin Phone: +353-1-820-3000 Fax: +353-1-820-9790

Israel – Yokneam Phone: +972-4-959-0508 Fax: +972-4-959-0506

Italy – Collegno (Torino) Phone: +39-011-4012-111 Fax: +39-011-4031116Product Information Center:Phone: +39-011-4012-360 Fax: +39-011-40287360

Lithuania – Vilnius Phone: +370-5-2131-402Fax: +370-5-2131-403

Netherlands – ’s-Hertogenbosch Phone: +31-73-6246-246 Fax: +31-73-6212-365 Product Information Center:Phone: +31-73-6246-999 Fax: +31-73-6246-998

Norway – Nesbru Phone: +47-66-77-88-86 Fax: +47-66-77-88-55

Poland – Warsaw Phone: +48-22-4576-700 Fax: +48-22-4576-720Product Information Center:Phone: +48-22-4576-704 Fax: +48-22-4576-720

Romania – Bucharest Phone: +40-21-311-3479 + 3596 Fax: +40-21-312-0574

Russia – Moscow Phone: +7-095-926-55-06…09Fax: +7-095-926-55-05

Russia – St. Petersburg Phone: +7-812-718-8192 Fax: +7-812-718-8193

Slovenia – Ljubljana Phone: +386-1561-3270 Fax: +386-1561-3240

South Africa – Port Elizabeth Phone: +2741-503-4500 Fax: +2741-581-0440

Spain – Barcelona Phone: +34-93-291-0330 Fax: +34-93-201-7879

Sweden – Upplands Väsby Phone: +46-8-50-72-50-00 Fax: +46-8-50-72-50-01

Switzerland – Steinach Phone: +41-71-447-0447 Fax: +41-71-447-0444

Turkey – Istanbul Phone: +90-212-281-8181…3

+90-212-282-5130/5430Fax: +90-212-281-8184

Ukraine – Kiev Phone: +380-44-206-2265 Fax: +380-44-206-2264

T Y C O E L E C T R O N I C S G L O B A L C O N T A C T S

A M E R I C A S

A S I A / P A C I F I C

E U R O P E / M I D D L E E A S T / A F R I C A

Tyco Electronics AMP GmbH certified according ISO 14001 and ISO/TS 16949:2002

© 2005 Tyco Electronics AMP GmbH • AMPèrestr. 12–14, 64625 Bensheim • Phone +49-6251-133-0, Fax +49-6251-133-16001308086 - 3.0M - ST - Issued 08-05 Printed in Germany www.tycoelectronics.com