Non-Contact Magnetoelastic Pressure Sensing for Moving Objects: Overcoming Low Magnetic Permeability via High-Frequency Excitation

Non-contact pressure measurement for moving objects is critical in dynamic systems across aerospace, automotive, and robotics industries. Conventional contact-based sensors (e.g., strain gauges, piezoelectric, and capacitive sensors) introduce mechanical interference by altering structural stiffness, modifying dynamic response frequencies, and incurring reliability degradation due to cable-induced wear. To address these limitations, this study proposes a magnetoelastic effect-based non-contact pressure sensor utilizing high-frequency excitation (not less than hundreds of kilo hertz) to overcome the low magnetic permeability challenge of cost-effective materials. A force-magnetic-electric multiphysics coupling model is established to characterize the dynamic hysteresis and energy dissipation mechanisms under high-frequency conditions, incorporating fractional derivatives to account for skin-effect-induced eddy current losses. Systematic optimization of sensor configurations and excitation parameters is conducted through finite element simulations and experimental validation. The proposed sensor achieves a linear measurement range of 0–1500N with a sensitivity of 0.294mV/N, demonstrating a maximum repeatability error of 3.53%. The theoretical and experimental framework presented herein provides a foundation for future designs of high-frequency magnetoelastic sensors in industrial applications.