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GS82-AA02 E-Bike Speed Sensor

With the increasing popularity and growing trend of e-bikes, bicycle system suppliers have set goals to optimize power and performance of their drive systems. In order to support the driver in the best possible way, sensors are needed to deliver the required data and therefore adapt the engine's power support. An essential component is the ZF e-bike sensor for measuring the current speed, which is based on Hall technology with significant advantages over conventional reed switches.

Especially for high-quality e-bikes, all components need to be functional, from the drive to the battery and cabling. This is also the case with the ZF e-bike sensor. Speed sensors of the GS series have been specially developed for use in Pedelecs and S-Pedelecs. The extremely compact design meets the necessary requirements for the use in e-bikes.

The sensors are based on the principle of Hall-effect and therefore they are non-contact and durable. In combination with ferromagnetic target wheels, a high-resolution speed measurement with over 50 pulses per revolution can be implemented without any problems. In practice, this leads to a finer and quicker response from the e-bike drive - especially at lower speeds (e.g. when starting up a hill). The differential measurement of the magnetic flux also increases the robustness of the sensor against vibrations. In addition, there is no need for an external magnet, which is used with conventional reed switches. These are frail against even slight shifts on the spoke, which leads to functional failures and shut down of the drive unit.

The GS82-AA02 sensor is compact at 21.75mm length, 9.35mm diameter. As an interface to the drive system, the Higo connector has a cross-section of only 0.14mm² and due to its small size is prevalent in the e-bike industry. Depending on the customer's requirements the contact via connector, as well as the cable length, can be preselected individually. The sensor requires a constant voltage supply of 6.5 - 20 VDC and measures frequencies between 1 and 2,500 Hz. They are designed for a temperature range from -25 ° C to + 85°C to fulfill the declaration of conformity in the e-bike industry.  This sensor was originally developed for ABS applications. In addition to e-bikes, other target markets include e-scooters and various sports equipment for this small and efficient sensor.

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In recent years, the topic of sustainability has gained enormous importance throughout ZF. Our greatest impact worldwide lies in the technologies we provide.

Energy harvesting technology is part of this commitment to provide an alternative solution to an ever-increasing world of smart home technology, building automation and industrial installations.

ZF’s battery-free and wireless RF pushbutton module is now being celebrated with the launch of ZF’s stamp ‘Energy Harvesting by ZF’. Partners can use ZF’s new stamp to help market their products using the compact generator by highlighting their commitment to a sustainable technology.

Wireless / Battery-Free / Maintenance-Free:
A tiny and compact generator (20.1 x 7.3 x 14.3 mm) produces enough energy by pressing the button by means of induction, so that it can reliably transmit RF commands to a paired receiver. As a wireless solution it guarantees flexibility and the possibility to retrofit easily according to individual requirements. As a battery-free solution and with a lifetime of 1,000,000 switching cycles, maintenance and disposal requirements of battery replacements can be avoided.

The RF light switch module from ZF is the only one which is directly compatible with the RF standard KNX-RF and it supports the RF standard EnOcean3.0 too. In cooperation with onsemi, ZF has published a reference design for an Energy Harvesting Bluetooth5.0® Low Energy switch and a demo light switch module. It is compatible with standard frames and can also be combined with customer-specific control and design panels.

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Flexibility, Cost & Energy Efficiency in Smart Home

Big topics of discussion within the lighting sector include sustainability, energy efficiency, low cost systems, connectivity and convenience through flexibility.

One solution to address these issues, is the wireless and battery-free RF pushbutton module designed by ZF.

For the connection between lighting components and pushbuttons in buildings, cables are the established solution. This variant seems to be cheap and simple to install at first. Unfortunately, the initial low maintenance can quickly turn into an expensive undertaking. Installing cables creates inflexibility. As soon as it comes to modifying buildings updating cables between lights, actuators or sensors, it involves a huge effort and cost. Renovations require planning, knocking down walls, laying new wires and returning the building to its previous state.

ZF offers a sustainable alternative based on RF and completely free of batteries and wires. This concept eliminates the disadvantages of wired and battery powered systems. A tiny and compact generator (20.1 x 7.3 x 14.3 mm) produces enough energy by pressing the button by means of induction, so that it can reliably transmit RF commands to a paired receiver. As a wireless solution it guarantees flexibility and the possibility to retrofit easily according to individual requirements. As a battery-free solution and with a lifetime of 1,000,000 switching cycles, maintenance and disposal requirements of battery replacements can be avoided.

The RF light switch module from ZF is the only one which is directly compatible with the RF standard KNX-RF and it supports the RF standard EnOcean3.0 too. In cooperation with onsemi, ZF has published a reference design for an Energy Harvesting Bluetooth5.0® Low Energy switch and a first demo light switch module. It is compatible with standard frames and can also be combined with customer-specific control and design panels.

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Intelligent lighting systems are key drivers for the rapidly growing global smart home sector. These not only have to be energy-efficient, sustainable, and cost-effective, but also connected for increased flexibility. Therefore, ZF decided to join the EnOcean Alliance in spring 2021 to join this growing market. This enables the expansion of ZF’s energy self-sufficient product portfolio with a wireless and battery-free light switch module with EnOcean3.0 protocol.

With its energy harvesting product range, ZF offers a sustainable alternative to traditional systems - based on radio and completely free of batteries and cables. ZF aims to promote this sustainable trend with new products especially for smart homes and the lighting sector. An essential step is to expand the light switch portfolio with commercially available protocols, to enable the switch to be integrated in commercial buildings. Beyond the unique energy harvesting KNX light switch module, ZF offers now a light switch module that can be fully integrated into existing EnOcean3.0 wireless systems. The EnOcean3.0 radio protocol is designed for a frequency band of 868MHz (EU, Asia) and 915MHz (USA). Within buildings, low frequencies are particularly suitable for penetrating walls or ceilings and ensure reliable radio transmission. In addition, the radio range is up to 30 meters inside the building. The wireless light switch modules from ZF are compatible with standard frames available on the market and can also be combined with customer-specific control and design panels.

In addition to light switch modules, customer-specific solutions can also be developed based on the EnOcean3.0 protocol for Smart Home applications. One example is connected doors and windows which transmit signals for ambient condition monitoring. Another application is for smart industrial switches and stop request buttons in buses which can transmit specific commands via RF to factory workers and bus drivers. The core component of these energy harvesting radio modules is a small generator (20.1 x 7.3 x 14.3 mm), which creates enough energy by means of induction and by pressing a button, so that a radio signal can be transmitted to a receiver. As a wireless solution, these radio modules offer flexibility and design freedom in order to accomplish individual requirements. As a battery-free solution and with a lifetime of up to 1,000,000 switching cycles, costly maintenance and disposal of replaced batteries can be avoided.

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ZF E-bike Speed Sensor Enriches the New Trend of ABS Applications

The ABS system has become indispensable in passenger and commercial vehicles. This safety function is also becoming increasingly popular for e-bikes. Bicycle accidents are often caused by uncontrolled braking, especially during emergency stops or braking on gravel and wet roads. The anti-lock braking system ensures a safe slowdown by evenly deaccelerating the front and rear wheels. To do this, the speed on both wheels must be measured constantly and precisely. The Hall-based speed sensor from ZF promotes this solution.

The ZF e-bike speed sensor GS82-AA02 was specially developed for use in Pedelecs and S-Pedelecs. Based on Hall technology, the sensor in combination with an external, ferromagnetic speed disk achieves a high-resolution speed measurement. The sensor targets the slot structure of the speed disc and, depending on the number of slots, it transmits up to 50 or more speed signals per wheel revolution. In practice, this leads to a finer and quicker response from the e-bike drive. The ABS system also benefits from the high resolution in speed. With the precise speed values of both wheels, the ABS control unit can adjust the wheels to each other and brake them in a controlled manner.

The extremely compact design (21.75mm long x 9.35mm in diameter) of the sensor fulfills the necessary requirements for the use in e-bikes. The speed sensor is based on the principle of the Hall effect and therefore it is contactless and wear-free. The differential measurement of the magnetic flux also increases the robustness of the sensor against vibrations. Depending on the customer's requirements the contact via connector, as well as the cable length, can be preselected individually. The sensor requires a constant voltage supply of 6.5 - 20 VDC and measures frequencies between 1 and 2,500 Hz. They are designed for a temperature range from -25 °C to + 85 °C to fulfill the declaration of conformity in the e-bike industry.

Characteristics
• Hall based non-contact and solid-state sensor
• Virtually unlimited life, no wear and tear from friction
• Immune to vibration, shock, dirt or water for an improved functional safety especially for Pedelecs, S-Pedelecs and E-Scooter
• Available standard product with Higo connector. Flexibility in terms of cable length and connector assemblies.
• High resolution in combination with speed and brake disk especially for slow speeds (e.g. hill starts)
• Hall sensor with speed disk for improved manipulation resistance and robustness
• Best suitable also for ABS-Systems

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Bus Stop Buttons Are Now Wireless & Battery-Free Using Energy Harvesting Technology from ZF

Thanks to the wireless and battery-free switch technology from ZF, there are various possible application fields to increase connectivity, flexibility, and convenience. Bus stop buttons are another smart application integrating the inductive RF generator module. The target is to avoid cabling (up to 100m) and expensive maintenance work caused by cable breaks in buses. The energy harvesting switch guarantees design freedom and reduces maintenance work to a minimum as it has a lifetime of over 1,000,000 switching cycles.

The energy harvesting switch can be integrated directly into the plastic housing of the stop request buttons in buses. The compact design (20.1 x 7.3 x 14.3 mm) makes it easy to integrate. In addition, the ZF radio switch generates a voltage pulse by mechanical actuation as it relies on the inductive principle. Therefore, RF commands can be reliably sent via commercially available radio protocols such as EnOcean3.0 at a frequency band of 868MHz. In this case there is no risk of RF interference with Bluetooth devices which operate at a 2.4 GHz frequency range. Altogether, the radio switch is completely free of batteries or cabling, allows a reliable RF transmission and offers a high degree of flexibility when it comes to mounting in buses.

Each RF switch has a unique ID and can be programmed individually. This means that each stop request button can be assigned to a specific command group, such as opening doors at the front, back, or initiating measures for wheelchair users. The buttons are paired to the central receiver unit, which is again connected to the electrical bus system. Depending on the received command, the receiver triggers a visual or acoustic signal to give the bus driver appropriate instructions.

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Energy Harvesting can be described as an ‘operation without any auxiliary energy’, as the energy is generated from the surrounding environment and then converted.

Energy Harvesting Switch Solutions Technology is an energy harvesting switch which reacts to its environment without a need for energy. This solution developed by ZF is based on the principle of Energy Harvesting and does not require any wires. Energy Harvesting can be described as an ‘operation without any auxiliary energy’. Instead of generating auxiliary energy through an integrated energy source or adding it via an external energy supply, energy that is available in the surrounding environment or that is acting on the system is converted. Therefore an Energy Harvester generally speaking is an energy converter.

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The topics of sustainability, flexibility and energy efficiency in the lighting sector are the largest airports in China. Thanks to the wireless and battery-free light switch module from ZF, lights are controlled by using the KNX-RF radio protocol at Beijing and Xinjiang airports.

The first KNX light switch modules from ZF were installed and used in July 2016 at Hetian Airport in the city of Xinjiang. Due to the positive results, Beijing International Airport also expressed interest in the innovative modules. In September 2020 the time came - the energy harvesting light switches from ZF now control the lighting of the VIP rooms at the airport of the Chinese capital.

The reasons for using these innovative ZF light switch modules are varied, but simple. Based on RF and completely free of batteries and cables, the modules can be integrated into a KNX network. After short training, lights can be controlled via the ZF light switch in the same way as traditionally wired light switches. KNX-RF commands transmitted by the switches can be easily transformed into KNX-TP by means of a media coupler. As a wireless solution, however, the ZF light switch offers great flexibility and the option of redesigning the room division in the airport according to individual requirements. This avoids not only maintenance work in the future but also time-consuming measures for battery replacement and disposal. The technical core component of the ZF light switch module is located inside. A small, compact generator (20.1 x 7.3 x 14.3 mm) generates enough energy by mechanical actuation due to the inductive principle. This ensures a reliable radio transmission of commands. With a lifetime of over 1,000,000 switching cycles, it can be operated for many years without any problems.

The wireless light switch module from ZF is uniquely available for the KNX-RF wireless standard without an additional gateway. Due to the KNX protocol structure, the generator requires a high energy yield. With up to 330µWs, the generator from ZF is ideally suited for this application. In addition to KNX-RF, the ZF light switch module also supports the EnOcean3.0 wireless standard and the Bluetooth5.0 Low Energy. It is compatible with commercially available standard frames and can also be combined with customer-specific operating and design panels.

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Marine engine controls benefit from ZF Hall-based position sensors

Hall-based position sensors are becoming widely used in a wide variety of applications due to their contactless and wear-free measurement method. These sensors are used in outboard marine engines to control the trim level. Marine drive manufacturers rely on the Hall-based position sensors from ZF as reliable and robust components for their overall drive system.

The Hall-based position sensors from ZF have been established as a reliable sensor solution for marine applications, especially for the inclination and trim measurement of outboard motors. To ensure optimal performance of a boat depending on the speed, the outboard motor must have a certain inclination. Both angle and linear position sensors are used with an associated external magnet carrier to monitor and realign the current inclination of the motor. The sensors are completely contactless and have an almost unlimited lifetime, as no wear and tear occur caused by abrasion. For position measurement, the external magnet is attached a few millimeters above the sensor. If the magnet rotates, the magnetic field changes, which again leads to a change in voltage within the sensor electronics. Each voltage value can be assigned to a specific angle value.

Depending on the requirements and customers’ requests, ZF offers a range of different angle sensor variants with associated magnets for triggering signals. These vary in terms of the angular range (0-360°), signal redundancy (non-, semi- or fully redundant), connection interface (cable, connector), operating temperature range and form factor. Attributed to long lasting experiences and know how in hall-based sensor technology, also customized solutions can be fulfilled.

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