Magnetic encoding for smart position sensor range extension

An extended range position sensor comprising:

• a source carrier comprising:
• a plurality of magnets fixedly coupled to the source carrier, the magnets being cascaded in a first predetermined spatial relationship relative to one another, wherein the first predetermined spatial relationship includes variable spacings between the plurality of magnets, wherein each magnet in the plurality of magnets is arranged in one of at least two distinct predetermined orientations, wherein the at least two distinct predetermined orientations comprise an axial orientation and a radial orientation;
• and,
• a reference carrier comprising:
• a plurality of magnetic field sensors fixedly coupled to the reference carrier, the magnetic field sensors being cascaded in a second predetermined spatial relationship relative to one another,
• wherein the plurality of magnets and the plurality of magnetic field sensors are configured to move relative to one another,
• wherein the plurality of magnetic field sensors are configured to generate a plurality of output signals, the plurality of output signals being a function of:
• (1) relative positions between the plurality of magnets and the plurality of magnetic field sensors, and (2) the predetermined orientations of the plurality of magnets,
• wherein the plurality of output signals are configured to be encoded as one of a finite number of codes, wherein each code in the finite number of codes corresponds to a specific relative position between the plurality of magnets and the plurality of magnetic field sensors.

An extended range position sensor comprising:

• a source carrier comprising:
• a plurality of magnets fixedly coupled to the source carrier, the magnets being cascaded in a first predetermined spatial relationship relative to one another, wherein the first predetermined spatial relationship includes variable spacings between the plurality of magnets, wherein each magnet in the plurality of magnets is arranged in one of at least two distinct predetermined orientations, wherein the at least two distinct predetermined orientations comprise an axial orientation and a radial orientation;
• a reference carrier comprising:
• a plurality of magnetic field sensors fixedly coupled to the reference carrier, the magnetic field sensors being cascaded in a second predetermined spatial relationship relative to one another;
• and,
• a controller configured to determine an encoded code corresponding to a specific relative position between the plurality of magnets and the plurality of magnetic field sensors,
• wherein the plurality of magnets and the plurality of magnetic field sensors are configured to move relative to one another,
• wherein the plurality of magnetic field sensors are configured to generate a plurality of output signals, the plurality of output signals being a function of:
• (1) relative positions between the plurality of magnets and the plurality of magnetic field sensors, and (2) the predetermined orientations of the plurality of magnets,
• wherein the plurality of output signals are configured to be encoded as one of a finite number of codes, wherein each code in the finite number of codes corresponds to a specific relative position between the plurality of magnets and the plurality of magnetic field sensors.