TDK launches new Hall sensor for EV motors

TDK Corporation has recently expanded its Micronas Hall-effect sensor portfolio with the introduction of the HAL 3025. This new sensor is specifically designed to be stray-field robust, making it ideal for high-speed motor control applications in electric vehicles and safety-critical automotive systems.

The HAL 3025 sensor offers analog sine/cosine outputs along with ASIL D-ready functional safety support. It is tailored for applications such as steer-by-wire, brake-by-wire, and high-voltage traction motors. Samples of the sensor are already available, and volume production is set to commence in Q2 of 2026.

For engineers and professionals working on electric vehicle architectures and industrial motor systems, the launch of the HAL 3025 sensor underscores the increasing need for compact and highly integrated sensors that can operate reliably in electrically noisy environments. It also reflects the efforts of sensor suppliers to streamline compliance with stringent automotive functional safety standards.

Designed for high-speed EV motor control

The HAL 3025 sensor is capable of measuring full 360° rotational position using TDK-Micronas’ SixSense technology. This innovative technology evaluates the vertical magnetic field component while effectively suppressing external DC and AC stray fields in accordance with ISO 11452-8 requirements.

With the ability to operate at rotational speeds of up to 60,000 rpm, the sensor is well-suited for modern electric powertrains and fast-response actuators. TDK emphasizes that the analog signal path of the sensor ensures low latency and high bandwidth, enabling precise calculation of angular position by external ECUs or microcontrollers using differential or single-ended sine/cosine outputs.

One of the primary objectives in the design of the HAL 3025 sensor is to reduce system complexity in safety-critical architectures. TDK has developed the sensor as a single-die component that is ASIL D-ready under ISO 26262:2018. It integrates on-chip diagnostics for wire-break and overvoltage detection, eliminating the need for additional board space and bill of materials associated with multi-die solutions.

Stray-field immunity cuts shielding requirements

TDK is also promoting the HAL 3025 sensor as a solution to simplify motor layout design in compact electric vehicle systems where sensing elements are in close proximity to power electronics.

By compensating for magnetic interference from nearby motors and power lines, the sensor can eliminate the necessity for magnetic shielding or oversized magnets. The HAL 3025 sensor is compatible with a simple two-pole ferrite magnet in an end-of-shaft configuration.

The sensor includes programmable non-volatile memory for calibration parameters such as gain, offset, orthogonality, and 0-angle adjustment. These settings can be configured through the output pin, eliminating the requirement for dedicated programming pins during end-of-line calibration.

Enclosed in an SOIC8 footprint that is compatible with existing HAL 3020 and HAL 3021 devices, the sensor can operate across a junction temperature range of -40°C to 170°C. This makes it suitable for harsh automotive environments and next-generation x-by-wire vehicle architectures.