Precision Calibration for Dual Rotary Triggers

Problem

Manual calibration of Hall effect sensors in motor controllers produced variable commutation behavior and inconsistent trigger sensitivity.

Constraints

• Sensor output depended on precise trigger position.
• Calibration values had to be stored in the unit under test.
• The method had to be repeatable across production units.
• Manual technique variability needed to be removed.

Engineering Decisions

• Designed an automated sequence using a controlled actuator to position triggers.
• Measured sensor output at defined positions and calculated offsets automatically.
• Programmed calibration values into unit memory.
• Verified sensitivity and hysteresis after calibration.

Validation

• Challenged the sequence across multiple units and trigger states.
• Verified programmed offset values through post-calibration functional testing.
• Confirmed output behavior against acceptance limits.

Risk & Mitigation

• Actuator misalignment could bias calibration; mitigated through fixture setup checks.
• Incorrect memory write could create field behavior issues; mitigated through read-back verification.
• Sensor drift could affect output; mitigated through final functional verification.

Outcome

The calibration process reduced manual variation and produced repeatable trigger response in production test.