Hall Effect Sensors are magnetic sensors which encode information into electrical signals to be
processed by electronic circuits. These sensors are solid state devices which means that the
sensors are an electronic device in which electricity is switched through solid semiconductor
crystals rather than mechanical contacts.

Hall Effect Sensors are the optimal solution due to their non-contact wear-free performance
which allows for low-maintenance and long life expectancy.

Magnetic sensors as such, are designed to respond to a variety of both positive and negative magnetic fields used within a
wide range of applications. The design of these sensors makes them resistance to dust, water
and vibration. Hall Effect Sensors are used in applications such as proximity switching,
positioning, speed detection and current sensing.

Hall Effect Sensors are more economical and reliable than mechanical switches. These sensors
can also be used under severe conditions due to their ingress protection which resists
environmental contaminants.

Markets using Hall Effect Sensors:

  • Automotive
  • Medical Devices
  • Energy and Power
  • Aquatic Applications
  • Aerospace
  • Pharmaceuticals
  • Engineering Equipment
  • Science and Analytical Instruments
  • Building and Construction
  • Agriculture
  • Food and Beverage
  • Information and Communications Technology
  • Electronics (Industrial and Personal)
  • Enterprise Systems
  • Exercise Machines
  • Air Conditioning units

Now that we have described how Hall Effect Sensors work and where they are used, they are of
little value until they are connected to an application. Two common locations for attachment
are to printed circuit board and to wire harnesses and cable assemblies. Attachment to a circuit
board provides for a safe and static location which works well when all the electronics are fit
into one location. On those occasions in which the sensor must be located in a much smaller
footprint, away from the controls, wires and cables provide a path for conducting the signal,
allowing for sensor placement elsewhere in the application. For purposes of this article, we will
spend time discussing MJM Industries’ advantages when utilizing a Hall Effect Sensor at the end
of a wire harness or cable assembly.

Attaching wires to the Hall Effect Sensors, MJM Industries has developed proprietary
equipment and methods utilizing reflow technology, ensuring uniform and reliable electrical
connection. Offering a large selection of wiring and cables options for your sensors, MJM
Industries utilizes quick change fixturing so that low volume/high mix applications can be
economically processed, while meeting the demand of short lead times.

Advantages of reflow technology include:

  • Cost effective
  • Multiple connections can be made simultaneously
  • Fast temperature ramp-up and cool-down
  • Accurate positioning of components
  • Closed loop temperature control
  • Suitable for low/high production
  • Reliable processing, consistent processing

Traditional soldering methods offer a chance for disconnection of parts during the heating and
cooling process. This is because there is no constant pressure on the components. This method
is no longer a productive technique used in mass production as quality assurance cannot be
promised. Increasing the complexity and rising quality standards have provided that manual
soldering techniques to no longer be accepted as a sufficient method. Some of the
disadvantages of traditional soldering methods:

  • Extreme flux residues can be a result
  • Reliable replication is not guaranteed
  • Requires skill of individual producing (may or may not be of good quality)
  • Higher thermal load due to small soldering tip/contact area

As the final manufacturing step (prior to testing), MJM Industries encapsulates each sensor
package with a potted or overmolded design. By enclosing the sensor, the connection points
receive shelter from dust and moisture (IP level dependant on materials used) and ensures that
the sensor legs receive protection from bending stresses. For those opportunities that require
logos, custom colors, intricate shapes or attachment points, overmolding provides the best