RV College of Engineering®

(Autonomous Institution Affiliated to VTU, Belagavi)

Tachometer/RPM Gauge using

Hall Effect Sensor
Experiential Learning Report

Submitted by
YASHVANTH B L – 1RV22AI063
P SHREYAS – 1RV22AI036
ALLAN SALDANHA – 1RV22AI006
ABHINAV – 1RV22AI001

ARTIFICIAL INTELLIGENCE AND

MACHINE LEARNING

Submitted to
Dr. Niranjana K M (22PY22C)
Prof. Somesh Nandi (22CS23)
Prof. Hemanth Kumar B (22MA21C)
 Table of Contents

Sl No. Contents Page No.

1. Introduction 1

2. Literature Review 2-5

3. Problem Statement 6
4. Objectives 6
5. Methodology and Working Principle 7-8
6. Components in Physics 9
7. Components in Mathematics 10 - 11
8. Embedded C Programming 13
9. Conclusion and Future Work 15

10. References 16
 Introduction

In today's fast-paced world, precise measurement and control of machinery and

engines are critical for efficient operation, safety, and performance
optimization. One essential component for achieving this precision is a
tachometer, a device used to measure the rotational speed of an engine or any
rotating object. Traditional tachometers, which rely on mechanical means, have
been widely used for decades. However, they come with limitations in terms of
accuracy, reliability, and maintenance.
The Hall Effect sensor, on the other hand, is a non-contact technology that can
detect the presence and strength of a magnetic field. When applied to
tachometry, it allows for precise measurement of rotational speed without the
need for physical contact with the rotating object. This property makes Hall
Effect sensors an ideal candidate for modernizing tachometer design.
The project focuses on designing and building a tachometer or RPM
(Revolutions Per Minute) gauge utilizing a Hall Effect sensor. The integration
of a Hall Effect sensor adds accuracy and reliability to the RPM measurement
process.
This project is situated within the broader context of industrial automation,
automotive engineering, and machinery control systems. Accurate measurement
of rotational speed is crucial in various domains, including manufacturing,
transportation, and energy generation. A reliable and versatile tachometer can
significantly enhance the efficiency and safety of these systems.
Tachometers provide real-time feedback on rotational speed, allowing
operators, engineers, and users to make informed decisions, optimize
performance, enhance safety, and extend the lifespan of machinery and
equipment.
In the subsequent sections of this project, we will delve into the technical
aspects of our design, including the Hall Effect sensor's working principles, our
implementation methodology, and the benefits our tachometer offers in terms of
accuracy, versatility, and maintenance.

1
 Literature Review

AUTHORS PAPER PUBLICATION SUMMARY REMARKS

TITLE DETAILS

Kathirvelan J, Hall Effect International ● The research ● The authors

Babu Varghese, Sensor Based Journal of primarily focuses on provide a clear
Ubaid A Portable Computer the design, explanation of
Ponnary, Fajas Tachometer Science implementation of a the Hall Effect
Kamar, Renju for RPM and Engineering tachometer system sensor's
Thomas Jacob Measurement Communications- that utilizes Hall operation and
IJCSEC. Vol.2, Effect sensors to its integration
Issue.1, achieve non-contact into the
February,2014 RPM measurement. tachometer
● The paper offers system.
experimental results ● The paper
and performance addresses a
analysis of the Hall significant
Effect sensor-based problem in
tachometer. RPM
measurement
by introducing
an innovative
solution based
on Hall Effect
sensor.

Elsayed T. Design of Journal of Robotics ● The authors present ● The paper's

Helmy, Farhad Contact and and Control (JRC) two distinct approach offers
Waseel, Non-Contact Vol. 1, No. 3, tachometer designs: readers a
Tachometer May 2020 one utilizing contact- understanding
Using based methods and the of different
Microcontroller other utilizing non- methods for
contact methods. measuring
● The authors rotational
describe the technical speed.
details of both ● The paper
tachometer designs, provides
including the sensors adequate
used and the technical detail
microcontroller for both
configurations. tachometers,
enabling

2
 readers to
replicate the
systems.

Han-Chen Speed Control of 2016 ● This paper focuses ● The topic of

Wu, Min-Yi BLDC Motors International on the development speed control
Wen, and Using Hall Effect Conference on of a speed control for BLDC
Ching-Chang Sensors Based on System Science system for Brushless motors is highly
Wong DSP and Engineering Direct Current relevant in the
(ICSSE) (BLDC) motors context of
utilizing Hall Effect industrial
sensors and Digital automation and
Signal Processing electric
(DSP) techniques. propulsion
● The authors employ systems. The
Hall Effect sensors integration of
for position feedback, Hall Effect
and DSP is used to sensors and
process sensor data DSP technology
and control the is a
motor's speed. contemporary
approach that
aligns with
current trends.
● The inclusion
of experimental
results is a
strong point, as
it demonstrates
the practical
performance of
the proposed
system.
.

3
 Aman A low-cost wheel Indian Journal ● Hall effect
Mahore, H L slip measurement of Agricultural 1.The paper presents a sensor was
Kushwaha, device for Sciences, March low-cost wheel slip found the best
Adarsh Kumar agricultural tractors 2022 measurement device for for measurement
and Tapank agricultural tractors. The of rotational
Khura device consists of a Hall speed under
effect sensor, a
different
microcontroller, and an
working
indicator. The Hall effect
sensor is used to
conditions of
measure the rotational light and dust.
speed of the tractor ● The results
wheel. The obtained from
microcontroller is used the developed
to calculate the wheel device showed
slip. The indicator is that the values
used to display the wheel
were statistically
slip value to the tractor
close to actual
operator.
2.The authors tested the
values.
device on three different
types of agricultural
tractors: a 2WD tractor,
a 4WD tractor, and a
4WD tractor with a
PTO-driven implement.
The results showed that
the device was able to
accurately measure the
wheel slip of all three
tractors. The average
error of the device was
2.5%.

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 Problem Statement:
Harnessing the versatility of tachometers to achieve RPM optimization through an
innovative and effective Hall Effect sensor-based sustainable approach.
Tachometers are known for their versatility as they can be integrated into various types
of machinery and systems. They provide real-time data on RPM, which is essential for
monitoring and controlling operations. However, the challenge lies in harnessing this
versatility to achieve optimal RPM levels.
RPM optimization is crucial for several reasons. Operating machinery at the right RPM
ensures maximum efficiency, minimizes wear and tear on components, reduces energy
consumption, and often results in lower emissions. Achieving the optimal RPM
requires a precise and adaptable approach that can cater to different operational
conditions and requirements.
Hall Effect sensors are known for their reliability and accuracy in detecting changes in
magnetic fields, making them suitable for RPM measurement. The use of these sensors
can lead to more sustainable operations in various ways:

 Energy Efficiency: By accurately measuring RPM and adjusting it in real-time,

machinery can operate at the most energy-efficient speed, reducing overall
energy consumption.

 Component Longevity: Proper RPM optimization ensures that components

experience less wear and tear, extending their operational lifespan and reducing
maintenance and replacement costs.

 Emissions Reduction: In applications where emissions are a concern,

maintaining optimal RPM can lead to reduced emissions as engines and motors
operate more efficiently.

 Resource Conservation: Sustainable practices often involve conserving

resources, and optimizing RPM aligns with this goal by reducing unnecessary
resource consumption.

Objectives

● To devise and implement an efficient and sustainable tachometer system using a

Hall effect sensor to continuously monitor the rotational speed of propeller
blades.
● The system should offer real-time, precise, and reliable speed data to facilitate
optimization of blade speed for maximum energy conversion and reduced
mechanical stress, in regards to energy generation applications.
● This system should offer high accuracy, flexibility, and efficiency in monitoring
and fine-tuning rotational speeds to elevate productivity and sustainability
across industries.

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 Working Principle

 A Hall effect sensor is a semiconductor device that can detect changes in a

magnetic field. When exposed to a magnetic field perpendicular to its current
flow, it generates a voltage difference known as the Hall voltage. This voltage
is proportional to the strength of the magnetic field.
 As the propeller rotates, it generates a changing magnetic field due to the
interaction between the propeller blades and the Earth's magnetic field. This
changing field induces a voltage across the Hall effect sensor.
 The Hall effect sensor detects this induced voltage and converts it into an
electrical signal. The frequency of the signal corresponds to the propeller's
RPM. The sensor's output signal is then processed to extract the RPM
information.

Methodology
 Mount the Hall effect sensor near the hub of the propeller assembly and ensure
that the sensor is oriented so that the magnetic field lines from the rotating
blades pass through the sensor in a perpendicular direction.
 Connect the output of the Hall sensor to the input of the Arduino board and set
up the microcontroller development environment.
 Read the analog signal from the conditioned output of the Hall effect sensor
using the microcontroller's analog-to-digital converter (ADC) inputs. Convert
the analog signal to a digital value.
 Calculate the time between consecutive high and low transitions of the digital
signal. This time interval corresponds to one complete rotation of the propeller.
RPM is calculated using the formula: RPM = (60 / Time) * Number of Blades
 Set an optimal RPM range based on the specific application's requirements and
efficiency characteristics. Compare the calculated RPM with the optimal RPM
range.
 If the calculated RPM is outside the optimal range, trigger corresponding LED
and buzzer alarms.
 Simultaneously, a motor driver is used to adjust the rotational speed of the
propeller.
 Depending on the application, RPM can be adjusted through appropriate
means:
a) In a propeller-driven vehicle, adjust the engine throttle.
b) In a wind turbine, adjust the pitch angle of the blades.

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 Implement a feedback loop to continuously monitor RPM and make real-time
adjustments.

Requirement
Analysis and
Procurement of • PHASE I
necessary
components

Designing, Modelling
and Testing of the • PHASE II
Prototype

Optimization,
Troubleshooting and
Assembly of final • PHASE III
model

CIRCUIT DIAGRAM

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 Components in Physics

● Hall Effect Principle:

The Hall Effect principle describes the generation of a voltage perpendicular to
the direction of current flow in a conductor or semiconductor when it is subjected
to a magnetic field. This phenomenon is the basis for Hall Effect sensors, which
are essential components in many electronic and industrial applications for
measuring and detecting magnetic fields and currents.
The Hall effect sensor detects the induced Hall voltage and converts it into an
electrical signal. The frequency of the signal corresponds to the propeller's RPM.

● Magnetic Field Interaction:

The Hall effect sensor is positioned in close proximity to the propeller's
rotational axis, ideally near the hub. It is oriented so that the magnetic field lines
created by the spinning propeller pass through the sensor in a perpendicular
fashion. As the rotating magnet spins, it produces a changing magnetic field.
This field changes in strength and direction as the magnet rotates past the Hall
Effect sensor. The faster the magnet passes by, the more pulses the Hall effect
sensor will generate, which can be used to calculate the RPM.
The Hall Effect sensor in a tachometer interacts with the changing magnetic field
produced by a rotating magnet to generate a Hall voltage. This voltage is directly
proportional to the rotational speed of the magnet, which is then processed and
displayed as RPM.

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 Components in Mathematics

● Frequency-to-RPM Conversion:
A mathematical relationship is obtained between the frequency of the sensor
signal (measured using a microcontroller's timer) and the RPM of the propeller.
Hence, a scale can be devised as follows:

● RPM Calculation:
The time between consecutive high and low transitions of the digital signal is
calculated. This time interval corresponds to one complete rotation of the
propeller. Calculations of RPM can be done using the formula:

RPM = (60 / pulse_time)

Distance travelled =(Circumference) × (RPM)

● Optimal RPM Range Calculation:

Mathematical calculations are used to define the optimal RPM range based on
application requirements.
Let's consider the application of centrifugal pumps.
Specific speed: The specific speed is a dimensionless parameter that is used to
characterize the performance of centrifugal pumps. It is defined as the speed at
which a pump would move 1 m^3/s of water against a head of 1 metre if it were
100% efficient. The optimal RPM range is the range where the specific speed is
highest.
The formula for specific speed is: Ns = (Q * H)0.5/ (g * D)

where: Ns is the specific speed, Q is the flow rate (m3/s), H is the head (m), g is
the acceleration due to gravity (9.81 m/s2), D is the impeller diameter (m)

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 • Affinity laws: The affinity laws are a set of equations that relate the performance
of a centrifugal pump to its speed, impeller diameter, and head.

The affinity laws are: Q = k * N3 H = k' * N2 D = k'' * N

where k, k', and k'' are constants that depend on the design of the pump.

For example, let's say we have a centrifugal pump with a specific speed of 100. We
need the pump to move 10 m3/s of water against a head of 10 meters. Using the affinity
laws, we can calculate that the RPM range that will meet the flow rate and head
requirements is 1000 to 1200 RPM.

GRAPHS SHOWING DEPENDENCY OF OPTIMUM RPM ON VARIOUS FACTORS

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 Components in PIC

● Sensor Interface:
Embedded C programming is used to read analog signals from the Hall effect
sensor through the microcontroller's ADC pins.
Functions such as readSensor(sensorPin) which takes input signals from the output
of the Hall effect sensor and reads these values into the microcontroller memory,
are some examples of functions used in sensor interfacing.
● RPM Calculation Logic:
The logic to calculate RPM is coded using the formula derived from the
mathematical component.
While loops and functions like initialiseTimer(), calculateRPM() are used in the
RPM calculation logic. They return values which are further used as arguments in
upcoming functions.
● Feedback Control Logic:
Code is developed to compare calculated RPM with the desired range, trigger
adjustments, and control propeller speed through a motor driver.
Feedback logic is the most important coding component as it involves triggering
specific actions at specific conditions. The most important is the blinking LED
alarm and buzzer which is accompanied by gradual change in speed by the
adjustRPM() function.

ARDUINO PROGRAM(CODE) FOR TACHOMETER

#include <SPI.h>
#include <Wire.h>
#include <Adafruit_GFX.h>
#include <Adafruit_SSD1306.h>

#define SCREEN_WIDTH 128 // OLED display width, in pixels

#define SCREEN_HEIGHT 64 // OLED display height, in pixels

// Declaration for SSD1306 display connected using I2C

#define OLED_RESET -1 // Reset pin # (or -1 if sharing Arduino reset pin)
#define SCREEN_ADDRESS 0x3C
Adafruit_SSD1306 display(SCREEN_WIDTH, SCREEN_HEIGHT, &Wire, OLED_RESET);

// Motor A connections
int enA = 10;
int in1 = 9;
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int in2 = 8;
int pot = A3; // Potentiometer pin
int buz =11; // Buzzer pin
int rled=5; // Red LED pin
int gled=6; // Green LED pin
int hall=3; // Hall effect sensor pin

int tON=0;
int tOFF=0;
int Tperiod=0;
int freq=0;
int RPM=0;

// Function to blink LED and buzz a buzzer a specified number of times

void blinkAndBuzz(int rledPin, int buzPin, int times) {
for (int i = 0; i < times; i++) {
digitalWrite(rledPin, HIGH);
digitalWrite(buzPin, HIGH);
delay(100);
digitalWrite(rledPin, LOW);
digitalWrite(buzPin, LOW);
delay(100);
}
}

void setup() {
// Set all the motor control pins to outputs
pinMode(enA, OUTPUT);
pinMode(in1, OUTPUT);
pinMode(in2, OUTPUT);
pinMode(pot,INPUT);
pinMode(buz,OUTPUT);
pinMode(rled,OUTPUT);
pinMode(gled,OUTPUT);
pinMode(hall,INPUT);

// Turn off motors - Initial state

digitalWrite(in1, LOW);
digitalWrite(in2, LOW);

Serial.begin(9600);

// initialize the OLED object

if(!display.begin(SSD1306_SWITCHCAPVCC, SCREEN_ADDRESS)) {
Serial.println(F("SSD1306 allocation failed"));
for(;;); // Don't proceed, loop forever
}
display.clearDisplay();
}

void loop() {
// Turn on motor A
digitalWrite(in1, HIGH);
digitalWrite(in2, LOW);

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// Read potentiometer value and map it to motor speed
int potval=analogRead(pot);
int mval=map(potval,0,1023,0,255);
analogWrite(enA,mval);

// Calculate frequency and RPM using pulseIn function

tON=pulseIn(3,HIGH);
tOFF=pulseIn(3,LOW);
Tperiod=tON + tOFF;
freq= 1000000.0/ Tperiod;
RPM=freq * 60;

// Display RPM and frequency on OLED if hall effect sensor reads HIGH
if(digitalRead(3)==HIGH)
{
display.clearDisplay();
display.setCursor(0, 0);
display.print("RPM METER ");
display.setCursor(0, 10);
display.print("Frequency: ");
display.print(freq);
display.println(" Hz");
display.setCursor(0, 20);
display.print("RPM: ");
display.println(RPM);
display.display();
delay(100);
display.clearDisplay();
}

// If RPM exceeds 5000, blink LED and buzz buzzer, then reduce motor speed
while(RPM>5000){
digitalWrite(gled, LOW);
blinkAndBuzz(rled, buz, 10); // Blink and buzz 10 times
potval=800;
mval=map(potval,0,1023,0,255);
analogWrite(enA,mval);
digitalWrite(gled, HIGH);
delay(5000);
}

// If RPM is below 300, turn off all indicators

if(RPM<300){
digitalWrite(rled,LOW);
digitalWrite(gled,LOW);
digitalWrite(buz,LOW);
}
else{
digitalWrite(rled,LOW);
digitalWrite(gled,HIGH);
digitalWrite(buz,LOW);
delay(100);
analogWrite(enA, mval);

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 }

// Print potentiometer value to serial monitor

Serial.println(potval);
delay(10);

// Reset all variables for next iteration

tON=0;
tOFF=0;
Tperiod=0;
freq=0;
RPM=0;
}

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 Conclusion

In conclusion, the implementation of the tachometer system using a Hall Effect

sensor has proven to be an effective and reliable method for RPM measurement in
various applications. Through this project, we have successfully demonstrated the
following key points:
 The Hall Effect sensor-based tachometer consistently provided accurate and
real-time RPM readings, allowing for precise monitoring and control of
rotational speeds.
 The versatility of Hall Effect sensors allowed us to adapt the system to
different types of machinery and rotating components, making it suitable for
a wide range of applications.
 The project showcased the cost-effectiveness of the Hall Effect sensor-based
approach compared to traditional RPM measurement methods, making it a
viable option for both small and large-scale implementations.

Future Scope:

While this project has been successful in achieving its objectives, there are several
avenues for further improvement and exploration:
 Enhanced Sensor Technology: Continuously monitor advancements in Hall
Effect sensor technology. Future sensors may offer higher sensitivity, lower
power consumption, and smaller form factors, improving overall system
performance.
 Integration with IoT: Explore the integration of the tachometer system with
the Internet of Things (IoT) for remote monitoring and data logging. This
would enable real-time tracking of RPM data and predictive maintenance.
 Wireless Communication: Develop wireless communication interfaces to
transmit RPM data to control systems and mobile devices, increasing
accessibility and usability.
 Machine Learning Integration: Investigate the use of machine learning
algorithms to analyze RPM data for predictive maintenance, anomaly
detection, and performance optimization.
 Industrial Applications: Focus on the application of the Hall Effect sensor-
based tachometer in industrial settings, such as manufacturing, where
precise RPM control is crucial for quality and efficiency.
 Miniaturization: Work on miniaturizing the system further to make it
suitable for smaller devices and equipment.
 Environmental Considerations: Explore the use of environmentally friendly
materials and power sources to align with sustainability goals.

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 References

[1] Kathirvelan J, Babu Varghese, Ubaid A Ponnary, Fajas Kamar, Renju Thomas Jacob, “Hall
Effect Sensor Based Portable Tachometer for RPM Measurement”, International Journal of
Computer Science and Engineering Communications- IJCSEC. Vol.2, Issue.1,
February,2014
[2] Elsayed T. Helmy, Farhad Waseel, “Design of Contact and Non-Contact Tachometer
Using Microcontroller”, Journal of Robotics and Control (JRC), Vol. 1, No. 3, May 2020
[3] Han-Chen Wu, Min-Yi Wen, and Ching-Chang Wong, “Speed Control of BLDC Motors
Using Hall Effect Sensors Based on DSP”, 2016 International Conference on System
Science and Engineering (ICSSE)
[4] Aman Mahore, H L Kushwaha, Adarsh Kumar and Tapank Khura, “A low-cost wheel slip
measurement device for agricultural tractors”, ICAR-Indian Agricultural Research
Institute, New Delhi, Indian Journal of Agricultural Sciences, March 2022
[5] Jia R C, Yang J S O, Lin H L and Chen J F, “A real-time differential anti strong
interference tachometer based on Arduino”, International Conference on Applied
Mechanics, Electronics, and Mechatronics Engineering (AMEME 2016). May 28–29,
2016. Beijing, China.
[6] Ma Zi Qin, Zhang Ren, Kang Da Li and Yang Wu, “A research of high precision rotational
speed measurement system based on infrared sensor and microcontroller”, Applied
Mechanics and Materials 278(80): 680–83.
[7] Negi A. 2017, “Tachometer Using Arduino and Hall Effect Sensor”, Indian Journal of
Science and Technology 9(38): 1–11
[8] Ming Chen Wu, Lee Jong Un, “Applications of Linear Hall-Effect Sensors on Angular
Measurement”, 2011 IEEE International Conference on Control Applications (CCA) Part
of 2011 IEEE Multi-Conference on Systems and Control Denver, CO, USA. September
28-30, 2011

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