Direct drive servovalve device with redundant position sensing and methods for making the same

A servovalve device, comprising:

• a servovalve motor having a stator and a rotor assembly configured to rotate relative to the stator;
• a valve member coupled to the rotor assembly;
• and
• a sensor assembly which includes:
• an interface configured to couple to a controller that controls the servovalve motor,
• a set of programmable Hall sensors coupled to the interface, and
• a collar coupled to the set of programmable Hall sensors, the collar carrying the set of programmable Hall sensors at an installation location which is (i) adjacent to the rotor assembly and (ii) fixed relative to the stator, the set of programmable Hall sensors being configured to provide a set of position signals to the controller through the interface, the set of position signals identifying a rotational position of the rotor assembly relative to the stator;
• wherein the collar is configured to fit around the rotor assembly, and wherein the collar defines a common sensing area at which at least a portion of each programmable Hall sensor is co-located;
• and
• wherein the collar and the set of programmable Hall sensors are configured to rotate about the rotor assembly of the servovalve motor and relative to the stator of the servovalve motor between a first rotational orientation and a second rotational orientation, the second rotational position aligning at least one Hall sensor of the set of programmable Hall sensors with a maximum torque position of the motor such that a null position of the at least one Hall sensor aligns with the maximum torque position of the motor,
• wherein each programmable Hall sensor of the set of programmable Hall sensors comprises a programmable circuitry portion, each programmable circuitry portion being configured to adjust the null position of the corresponding programmable Hall sensor such that the null position of the corresponding programmable Hall sensor is aligned with the maximum torque position of the servovalve motor;
• wherein the rotor assembly is operable to rotate clockwise and counterclockwise within an arc range between a first arc position and a second arc position to position the valve member linearly within a fluid pathway between a fully closed position and a fully open position;
• wherein the rotor assembly is operable to rotate clockwise and counterclockwise within a limited arc range that is less than 360° to position the valve member linearly within the fluid pathway between the fully closed position and the fully open position;
• and
• wherein each programmable Hall sensor of the set of Hall sensors is co-located in positional proximity to each other at the common sensing area defined by the collar such that at the second rotational position where the at least one Hall sensor of the set of programmable Hall sensors align with the maximum torque position of the motor such that the null position of the at least one Hall sensor aligns with the maximum torque position of the motor, the remaining Hall sensors of the set of Hall sensors are disposed in a substantially null position relative to the maximum torque position of the motor, and the set of programmable Hall sensors configured to provide redundant feedback;
• wherein:
• the maximum torque position of the motor comprises a position of the rotor assembly relative to the stator when the rotor assembly centers the valve member within a housing;
• and
• the null position of the corresponding programmable Hall sensor comprises a configuration of the corresponding programmable Hall sensor where the corresponding programmable Hall sensor generates an operational null value.