Dual current sensor with hall and shunt

Abstract

The present application relates to the technical field of resistance processing, and relates to a double current sensor with a Hall element and a shunt. A core electrode is arranged on an upper electrode, the upper electrode is provided with a resistance body, and a lower electrode is coiled to form a cylindrical body. The core electrode is connected with the upper electrode to form a shunt resistance structure. In use, current passes through the core electrode and the lower electrode to form a current path, thereby playing a role in detecting the current of a circuit board. A Hall element is arranged on the core electrode to detect the current on the core electrode. The two current detection schemes can also play a role in contrast self-checking, thereby enhancing the long-term reliability of the sensor as a whole. Meanwhile, the Hall element is arranged in a cavity to play a role in shielding interference, thereby increasing the adaptability of the product in installation and use.

Description

Technical Field

[0001] This invention relates to the field of resistance processing technology, and specifically to a dual current sensor with a Hall effect and a shunt. Background Technology

[0002] A current sensor is a device that can sense the current being detected and convert it into a usable output signal. It is typically used for detecting AC and DC currents.

[0003] Existing current sensors are generally based on the Hall effect principle. They use a Hall element to sense the magnetic field around the current being measured and convert it into an electrical signal. This signal is then processed by a series of circuits to output a suitable analog signal for current detection. However, these sensors have a low measurement range, are highly susceptible to environmental influences, and are inconvenient to install, failing to meet current requirements for miniaturization and lightweight design. Methods for measuring large currents typically involve passing the current through a shunt resistor. However, this method consumes too much power, generates significant heat, and affects detection accuracy. Furthermore, because existing current sensor structures are largely fixed, they cannot fully meet the specific installation or application requirements.

[0004] Therefore, to address the aforementioned technical problems, it is necessary to provide a dual current sensor with both Hall effect and shunt functions. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a dual current sensor with Hall effect and shunt that can shield Hall element from interference, increase the adaptability of the product in installation and use, and can also perform comparative self-test by using two current detection schemes in parallel.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0007] A dual current sensor with Hall effect and shunt, comprising:

[0008] A resistor includes a resistive element, a lower electrode is provided on a first side of the resistive element, the resistive element and the lower electrode are rolled into a cylindrical body, and an opening is provided at the top of the cylindrical body, and an upper electrode is provided on the opening.

[0009] A core electrode is disposed on the upper electrode and passes through the cavity of the cylindrical body;

[0010] A Hall element is disposed on the core electrode to detect the current on the core electrode.

[0011] In one embodiment of the present invention, the Hall element includes a magnetic core, the magnetic core being distributed around the outer wall of the core electrode, and a Hall coil being wound on the magnetic core, the Hall coil and the magnetic core forming a Hall sensing structure.

[0012] In one embodiment of the present invention, the upper electrode includes a cylindrical electrode sheet that matches the opening and is welded to the cylindrical body.

[0013] In one embodiment of the present invention, the cylindrical electrode includes a circular electrode and a connecting electrode. The connecting electrode is disposed on the second side of the resistive body. After the resistive body is rolled into a circle, the connecting electrode forms an annular structure. The circular electrode is welded to the edge of the connecting electrode.

[0014] In one embodiment of the present invention, the thickness of the circular electrode is 1.5-5 times the thickness of the connecting electrode.

[0015] In one embodiment of the present invention, the circular electrode and the connecting electrode are integrally formed by stamping the electrode material to form the circular electrode and the connecting electrode.

[0016] In one embodiment of the present invention, the core electrode is vertically disposed at the center of the circular electrode sheet, the core electrode is welded together with the circular electrode sheet, the core electrode is concentrically disposed with the cylindrical body, and the free end of the core electrode and the connecting end of the cylindrical structure are on the same plane.

[0017] In one embodiment of the present invention, the width of the lower electrode is 1 / 4 to 1 / 2 of the width of the resistive element.

[0018] In one embodiment of the present invention, at least one connecting groove is provided on the lower electrode, the connecting groove is connected to the cavity of the cylindrical body, and the lead wire of the Hall coil is led out from the cavity of the cylindrical body through the connecting groove.

[0019] In one embodiment of the present invention, the circular electrode is provided with a connecting hole, the fixed end of the core electrode passes through the connecting hole, and the fixed end of the core electrode is welded to the edge of the connecting hole.

[0020] The beneficial effects of this invention are:

[0021] In this invention, the core electrode is disposed on the upper electrode, which is fitted with a resistor and the lower electrode rolled into a cylindrical body. The core electrode is connected to the upper electrode to form a shunt resistor structure. In use, the current passes through the core electrode and the lower electrode respectively, thus forming a current path to detect the current on the circuit board. A Hall element is disposed on the core electrode to detect the current on the core electrode. The two current detection schemes can be used in parallel to perform a comparative self-test, enhancing the overall long-term reliability of the sensor. At the same time, placing the Hall element in a cavity can shield it from interference, increasing the adaptability of the product in installation and use. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a dual current sensor with Hall effect and shunt according to the present invention.

[0023] Figure 2 This is a cross-sectional view of the present invention.

[0024] The following are the labels in the diagram: 1. Cylindrical body; 11. Resistor; 12. Lower electrode; 121. Connecting groove; 122. Pin; 123. Connecting end; 124. Free end; 13. Cavity; 14. Lead wire; 2. Upper electrode; 21. Circular electrode; 22. Connecting electrode; 23. Fixed end; 3. Core electrode; 4. Hall element; 41. Magnetic core; 42. Hall coil. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0026] Reference Figure 1-2 As shown, a dual current sensor with Hall effect and shunt includes:

[0027] A resistor includes a resistive body 11, a lower electrode 12 is provided on a first side of the resistive body 11, the resistive body 11 and the lower electrode 12 are rolled into a cylindrical body 1, the top of the cylindrical body 1 is provided with an opening, and an upper electrode 2 is provided on the opening.

[0028] The core electrode 3 is disposed on the upper electrode 2 and passes through the cavity 13 of the cylindrical body 1;

[0029] Hall element 4 is disposed on the core electrode 3, and the current on the core electrode 3 is detected by Hall element 4.

[0030] The core electrode 3 of this invention is disposed on the upper electrode 2. The upper electrode 2 is disposed on a resistor 11 and a lower electrode 12 rolled into a cylindrical body 1. The core electrode 3 is connected to the upper electrode 2 to form a shunt resistor structure. In use, the current passes through the core electrode 3 and the lower electrode 12 respectively to form a current path and play the role of detecting the current of the circuit board. A Hall element 4 is disposed on the core electrode 3. The current on the core electrode 3 is detected by the Hall element 4. The two current detection schemes can be used in parallel to play a comparative self-test role, which enhances the long-term reliability of the sensor as a whole. At the same time, the Hall element 4 is disposed in the cavity 13, which can play a role in shielding the Hall element 4 from interference, increasing the adaptability of the product in installation and use.

[0031] The lower electrode 12 and the core electrode 3 of the present invention are inserted and mounted on the PCB board, which improves the reliability of resistor mounting and ensures that the resistor contacts the circuit board to provide a stable resistance value.

[0032] The current sensor of the present invention includes a Hall sensor and a shunt resistor, and has the function of dual current detection; moreover, the shunt resistor acts as a shell on the outside, which shields the internal Hall sensor from interference.

[0033] Reference Figure 2 As shown, in one embodiment of the present invention, the Hall element 4 includes a magnetic core 41, which is distributed around the outer wall of the core electrode 3, and a Hall coil 42 is wound on the magnetic core 41, forming a Hall sensing structure with the Hall coil 42 and the magnetic core 41.

[0034] Specifically, a Hall coil 42 is wound around the magnetic core 41, and the Hall coil 42 and the magnetic core 41 form a Hall sensing structure (Hall sensor). In use, the leads of the Hall sensing structure are connected to the detection circuit, which can detect the current passing through the magnetic core 41. The parallel operation of the two current detection schemes can also play a role in comparison and self-testing, thereby enhancing the overall long-term reliability of the sensor.

[0035] In one embodiment of the present invention, the upper electrode 2 includes a cylindrical electrode sheet that matches the opening and is welded to the cylindrical body 1.

[0036] Specifically, the cylindrical electrode sheet is welded to the cylindrical body 1, which makes the core electrode 3 more firmly connected to the upper electrode 2, with high strength and high stability.

[0037] In one embodiment of the present invention, the cylindrical electrode includes a circular electrode 21 and a connecting electrode 22. The connecting electrode 22 is disposed on the second side of the resistor 11. After the resistor 11 is rolled into a circle, the connecting electrode 22 forms an annular structure. The circular electrode 21 is welded to the edge of the connecting electrode 22.

[0038] Specifically, the lower electrode 12, the resistor 11, and the connecting electrode 22 are all welded together by vacuum electron beam. Rolling the three together can effectively reduce the number of process steps, reduce production costs, and enable mass production of resistors.

[0039] In one embodiment of the present invention, the thickness of the circular electrode 21 is 1.5-5 times the thickness of the connecting electrode 22.

[0040] Specifically, the thickness of the circular electrode 21 is 1.5-5 times the thickness of the connecting electrode 22, which can improve the strength of the upper electrode 2, make the structure more compact, and reduce manufacturing costs.

[0041] In one embodiment of the present invention, the circular electrode 21 and the connecting electrode 22 are integrally formed by stamping the electrode material to form the circular electrode 21 and the connecting electrode 22, wherein the electrode material is copper or brass.

[0042] Specifically, the electrode material is stamped to form a circular electrode 21 and a connecting electrode 22. The required structural shape of the semi-finished product is processed by stamping die, so as to realize the mass production of the upper electrode and ensure the consistency and stability of the product.

[0043] In one embodiment of the present invention, the core electrode 3 is vertically disposed at the center of the circular electrode 21, the core electrode 3 is welded together with the circular electrode 21, the core electrode 3 is concentrically disposed with the cylindrical body 1, and the free end 124 of the core electrode 3 and the connecting end 123 of the cylindrical structure are on the same plane.

[0044] Specifically, the core electrode 3 is vertically positioned at the center of the circular electrode 21, which can create a complete cylindrical shunt resistor structure, greatly saving electrode material and providing a reasonable spatial layout. The free end 124 of the core electrode 3 and the connection end 123 of the cylindrical structure are on the same plane, which is beneficial for mounting the resistor material on the circuit board and ensuring the performance of the resistor.

[0045] In one embodiment of the present invention, the width of the lower electrode 12 is 1 / 4 to 1 / 2 of the width of the resistor 11.

[0046] Specifically, the use of a larger area lower electrode 12 effectively increases the heat dissipation area of ​​the electrode and cavity 13, which not only enhances the electrical performance and reliability of the product and meets the requirements of high power resistance, but also prevents local overheating after loading, thus avoiding problems that affect the performance and lifespan of the resistor 11.

[0047] In one embodiment of the present invention, at least one connecting groove 121 is provided on the lower electrode 12, the connecting groove 121 is connected to the cavity 13 of the cylindrical body 1, and the lead wire 14 of the Hall coil 42 is led out from the cavity 13 of the cylindrical body 1 through the connecting groove 121.

[0048] Specifically, the connecting groove 121 on the lower electrode 12 allows the lead wire 14 of the Hall coil 42 to be easily led out from the cavity 13 of the cylindrical body 1 through the connecting groove 121. On the one hand, it facilitates the wiring arrangement of the lead wire 14, and on the other hand, it can avoid contact friction between the lead wire 14 and the resistor and the circuit board, so as to achieve the purpose of connecting the lead wire of the Hall sensing structure to the detection circuit, thereby transmitting the Hall signal to the corresponding control circuit board.

[0049] Meanwhile, the connecting groove 121 on the lower electrode 12 facilitates overall heat dissipation of the dual current sensor product on the circuit board. The connecting groove 121 can also dissipate heat for the Hall element 4 inside the cavity 13, which can meet the high power requirements and make its temperature change small during long-term operation.

[0050] Meanwhile, the smaller lower electrode 12 pin 122 formed between adjacent connecting slots 121 can also be conveniently positioned when the dual current sensor product is installed on the circuit board, improving assembly efficiency and facilitating circuit design with certain special requirements.

[0051] In one embodiment of the present invention, the circular electrode 21 is provided with a connection hole, the fixed end 23 of the core electrode 3 passes through the connection hole, and the fixed end 23 of the core electrode 3 is welded to the edge of the connection hole.

[0052] Specifically, a connecting hole is provided on the circular electrode 21. The connecting hole allows the fixed end 23 of the core electrode 3 to be installed. The core electrode 3 is exposed on the connecting hole, which facilitates the welding of the core electrode 3 to the upper electrode 2, thereby improving the welding quality. At the same time, the connecting hole can position the core electrode 3 to ensure the concentricity accuracy of the core electrode 3 and the cylindrical body 1. Its structure is simple, easy to operate, and highly safe, ensuring accurate welding and high stability.

[0053] When in use, the core electrode 3 is connected to the upper electrode 2 to form a shunt resistor; when in use, the dual current sensor product is installed on the circuit board, and the current passes through the core electrode 3 and the lower electrode 12 respectively to form a current path, which serves to detect the current of the circuit board.

[0054] Meanwhile, the cavity 13 of the cylindrical body 1 is surrounded by a magnetic core 41 distributed on the outer wall of the core electrode 3. A Hall coil 42 is wound on the magnetic core 41, and the Hall coil 42 and the magnetic core 41 form a Hall sensing structure (Hall sensor). In use, the lead wire of the Hall sensing structure is connected to the detection circuit, which can detect the current passing through the magnetic core 41. The parallel operation of the two current detection schemes can also play a role in comparison and self-testing, enhancing the overall long-term reliability of the sensor.

[0055] Electrical sensors based on the Hall effect principle and the shunt principle are suitable for measuring different current magnitudes. This solution combines the two approaches, enabling both high and low current detection, mutual monitoring and calibration, and providing double protection for current detection.

[0056] The above-described embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention. The scope of protection of the present invention is defined by the claims.

Claims

1. A dual current sensor with a Hall and shunt, characterized in that, The utility model relates to a kind of resistance, including resistor, the first side of the resistor is provided with lower electrode, the resistor and lower electrode are formed into cylindrical body by rolling, the top of the cylindrical body is provided with opening, and the upper electrode is provided on the opening;Core electrode is provided on the upper electrode, and the core electrode is arranged in the cavity of the cylindrical body;Hall element is provided on the core electrode, and the current condition on the core electrode is detected by the Hall element;The upper electrode includes cylindrical pole piece, the cylindrical pole piece is matched with the opening, and the cylindrical pole piece is welded together with the cylindrical body;The cylindrical pole piece includes circular pole piece and connecting pole piece, the connecting pole piece is arranged on the second side of the resistor, the connecting pole piece forms annular structure after the resistor is rolled, and the circular pole piece is welded together with the edge of the connecting pole piece;The width of the lower electrode is 1 / 4-1 / 2 of the width of the resistor. The Hall element includes magnetic core, the magnetic core is distributed on the outer side wall of the core electrode, the Hall coil is wound on the magnetic core, and the Hall coil and the magnetic core form Hall sensing structure. The thickness of the circular pole piece is 1.5-5 times of the thickness of the connecting pole piece. The circular pole piece and the connecting pole piece are integrally formed mechanism, and the electrode material is stamped to form the circular pole piece and the connecting pole piece. The core electrode is vertically arranged on the center of the circular pole piece, the core electrode is welded together with the circular pole piece, the core electrode is concentrically arranged with the cylindrical body, and the free end of the core electrode and the connecting end of the cylindrical structure are in the same plane. At least one connecting groove is formed in the lower electrode, the connecting groove is communicated with the cavity of the cylindrical body, and the lead wire of the Hall coil is led out from the cavity of the cylindrical body through the connecting groove. Connecting hole is arranged on the circular pole piece, the fixed end of the core electrode is arranged in the connecting hole, and the fixed end of the core electrode is welded together with the edge of the connecting hole.

2. The dual current sensor with Hall and shunt of claim 1, wherein, ​ 3. The dual current sensor with Hall and shunt of claim 1, wherein, ​ 4. The dual current sensor with Hall and shunt of claim 1, wherein, ​ 5. The dual current sensor with Hall and shunt of claim 1, wherein, ​ 6. The dual current sensor with Hall and shunt of claim 2, wherein, ​ 7. The dual current sensor with Hall and shunt of claim 1, wherein, ​

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