Tyco Electronics is a leading provider of sensor technologies for the automotive industry. They offer contactless sensor solutions that eliminate wear issues and provide increased reliability compared to contact sensors. Tyco has expertise in Hall effect, MR, PLCD, and temperature sensor technologies and can assist customers with selecting the appropriate technology and defining the mechanical, electrical, and magnetic interfaces for new sensor applications. Tyco provides sensors for applications such as automated transmissions, clutches, turbochargers, and various vehicle controls and measurements.

1. Sensor Technology
for the Automotive Market

2. 2

3. Tyco Electronics Ltd. is a leading global provider of engineered electronic
components, network solutions and wireless systems, with customers in more
than 150 countries. We design, manufacture and market products for customers
in industries from automotive, appliances and aerospace and defense to
telecommunications, computers and consumer electronics. With over 8,000
engineers and worldwide manufacturing, sales and customer service capabilities,
Tyco Electronics’ commitment is our customers’ advantage.
G LO B A L AU TO M OT I V E D I V I S I O N
S E N S O R T E C H N O LO GY
Contactless measuring eliminates interference effects, wear and tear,
and provides increased reliability. Tyco Electronics, one of the largest
technology providers for the automobile industry, offers contactless
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.
3

4. PLCD sensor element
for contactless travel and U-magnet concept for
angualr measurement magnetically biased sensors
SEMI-CONDUCTOR SEMI-CONDUCTOR MAGNETO-
A P P L I C AT I O N REQUIREMENTS SENSORS SENSORS INDUCTIVE
HALL EFFECT MR EFFECT PLCD SENSORS
T R AV E L MEASUREMENT
Operating range < 15 mm
Operating range > 15 mm
ANGLE MEASUREMENT
Tangential, operating range < 90˚
Axial, operating range > 90˚
SPEED MEASUREMENT
I N T E G R AT I O N REQUIREMENTS
Small Space
Large Operating range position tolerance
Large control distances (through structure walls)
ROBUSTNESS
High-precision performance with Mechanical load e.g. Vibration
High-precision performance with high ambient temperature
A U T O M O T I VAT E D I N E V E R Y D E TA I L
Our 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.
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5. TECHNOLOGY
Tyco Electronics has focused on contactless 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 contactless
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, PLCD Gear & Shift travel
sensor for Automated
whereas even driving distances through non-ferromagnetic walls
Manual Transmission
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.
Door Locking Unit with
integrated Hall-Devices
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6. COMPETENCIES
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.
FEM calculation for dimensioning the
magnetic sensor interface
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7. 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.
PLCD sensor module for gear Digital and linear position
and shift measurement measurement for clutch
master cylinder
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 E
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.
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8. A P P L I C AT 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 contactless 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 contactless 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
R E L AT E D T E C H N O L O G I E S
INDUCTIVE MECHATRONICS TERMINALS &
SYSTEMS CONNECTORS
8

9. PLCD travel Integrated PLCD Contactless Seat track position
sensor for travel sensor for throttle sensor (integrated
hydraulic pneumatic cylinder position sensor magnet)
cylinder
Contactless and redundant
brakelight switch (integrated magnet)
ALTERNATIVE CABLE ASSEMBLY HIGH SPEED POWER RELAYS & WIRELESS
POWER SYSTEMS SYSTEMS DATA NETWORKING DISTRIBUTION SWITCHING TECHNOLOGIES
SYSTEMS MODULES
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
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10. T YCO E L E C T R O N I C S “AT YO U R S E R V I C E ”
@ Tyco Electronics Online
The Tyco Electronics website is an innovative and
interactive source for application information,
product updates and technical solutions.
Our step-by-step software makes our website
intuitive and user-friendly to better serve you !
Please contact us at :
www.tycoelectronics.com/automotive
Internet Homepage
www.tycoelectronics.com
www.tycoelectronics.com/automotive Product Information Center
(PIC)
Electronic Internet Catalog
You can rely on Tyco Electronics PIC Team to
www.catalog.tycoelectronics.com
provide you support for answers to your
general information or technical questions in
an efficient and effective manner.
To reach our PIC staff, please contact your
local Tyco Electronics organization.
Product and Machine Literature
Tyco Electronics offers a variety of product specific catalogs, brochures
and high impact flyers to help better serve you !
For more information on literature for Tyco Electronics’
Global Automotive Division, please contact your local Tyco Electronics
Organization or go to www.tycoelectronics.com/automotive
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11. T YCO E L E C T R O N I C S G L O B A L C O N TA C T S
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Colombia – Bogota Countries not shown
Phone: +57-1-231-9398 Phone: +54-11-4733-2015 Troy, MI
Fax: +57-1-660-0206 Fax: +54-11-4733-2083 Phone: +1-248-273-3359
Fax: +1-248-273-3322
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Australia – Sydney Japan – Kawasaki, Kanagawa New Zealand – Auckland Singapore – Singapore
Phone: +61-2-9554-2600 Phone: +81-44-844-8111 Phone: +64-9-634-4580 Phone: +65-6482-0311
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Phone: +91-80-285-40800 Phone: +82-2-3415-4500 People’s Republic of China Thailand – Bangkok
Fax: +91-80-285-40820 Fax: +82-2-3486-3810 Hong Kong Phone: +66-2-955-0500
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www.tycoelectronics.com
11

12. Tyco Electronics AMP GmbH
AMPèrestr. 12-14
64625 Bensheim / Germany
Phone: +49-(0)6251-133-0
Fax: +49-(0)6251-133-1600
www.tycoelectronics.com
TE Logo and Tyco Electronics
are trademarks
Tyco Electronics AMP GmbH certified
acc. ISO 14001 and ISO/TS 16949:2002
© 2007 Tyco Electronics Ltd.
1308086-2 Rev. 12-2007 3.5M ST