Magnetic sensor with a magnetically sensitive component that is movable during calibration and rigidly attachable to a formed magnet

A magnetic sensor, comprising:

• a permanent magnet having first and second pole faces, said first and second pole faces being generally perpendicular to an axial centerline, said permanent magnet being a molded magnet;
• a channel formed in said permanent magnet along said centerline;
• a magnetically sensitive component disposed at least partially within said channel, said magnetically sensitive component having a sensing plane disposed in generally perpendicular association with said centerline;
• a substrate having an opening formed therethrough, said magnetically sensitive component being attached to said substrate;
• and
• a post attached to said permanent magnet and disposed through said opening of said substrate, said post being attached to said substrate to locate said magnetically sensitive component at a preselected position relative to said permanent magnet, said post being a metallic shaft molded into said permanent magnet, said preselected position being determined by monitoring an output from said magnetically sensitive component as said substrate is moved relative to said permanent magnet, said post being rigidly attached to said substrate when said output is generally equal to a predetermined magnitude.

A magnetic sensor, comprising:

• a permanent magnet having first and second pole faces, said first and second pole faces being generally perpendicular to an axial centerline, said permanent magnet being a molded magnet;
• a channel formed in said permanent magnet along said centerline;
• a magnetically sensitive component disposed at least partially within said channel, said magnetically sensitive component having a sensing plane disposed in generally perpendicular association with said centerline;
• a substrate having an opening formed therethrough, said magnetically sensitive component being attached to said substrate;
• and
• a post attached to said permanent magnet and disposed through said opening of said substrate, said post being attached to said substrate to locate said magnetically sensitive component at a preselected position relative to said permanent magnet, said post being a metallic shaft molded into said permanent magnet, said preselected position being determined by monitoring an output from said magnetically sensitive component as said substrate is moved relative to said permanent magnet, said post being rigidly attached to said substrate when said output is generally equal to a predetermined magnitude, said magnetically sensitive component comprising a Hall effect element, said post being attached to said substrate with solder, the edges of said permanent magnet, where said first pole face meets said channel, being beveled, said magnetically sensitive component being disposed completely within said channel and being formed as part of said permanent magnet.