System and method for reducing heat generation and power consumption of current sensor

Abstract

Systems and methods for reducing heat generation and power consumption of a current sensor. A method and apparatus including a magnetic core, a Hall effect sensor configured in an air gap of the magnetic core, an amplifier coupled to the Hall effect sensor, a driver coupled to the amplifier, a secondary winding including (i) a wire coil extending around the core and (ii) a first end coupled to the driver, and (iii) a switch coupled to the second end of the sampling resistor configured to allow a feedback current from the driver to the secondary winding, and a controller unit coupled to the switch, the controller unit configured to (i) receive a digital signal based on a sampled voltage associated with the sampling resistor, (ii) generate one or more control signals based on operating condition data comprising at least the digital signals exceeding one or more thresholds, and (iii) transmit the one or more control signals to the switch.

Description

Technical Field

[0001] Various embodiments of the present disclosure relate to current sensors, and more particularly, to varying the operation of a current sensor to control heat generation and power consumption. Background Art

[0002] Current sensors are employed in a wide variety of industrial and automotive applications. For example, monitoring of current is essential for the safety, performance, and efficiency of electric vehicles. However, current sensors are prone to overheating and high power consumption when used in high-current or high-voltage applications such as in electric vehicles. The applicant has recognized many technical challenges and difficulties associated with conventional current sensors. Summary of the Invention

[0003] Various embodiments described herein relate to components, devices, and systems for controlling a current sensor.

[0004] According to various embodiments of the present disclosure, a current sensor is provided. In some embodiments, the current sensor includes a magnetic core that includes (i) a core body and (ii) an air gap along the core body; a magnetic transducer disposed in the air gap; an amplifier coupled to the magnetic transducer; a secondary winding including a wire coil extending around the core body; and a switch coupled between the amplifier and the secondary winding, the switch being configured to open or close a circuit path between the amplifier and the secondary winding by operating in a continuous mode or a pulse mode based on a control signal.

[0005] In some embodiments, the amplifier is configured to receive an output voltage from the magnetic transducer; and generate an amplified voltage including a feedback current. In some embodiments, the switch is configured to allow the feedback current to flow from the amplifier via the circuit path to the secondary winding. In some embodiments, the continuous mode is associated with higher measurement accuracy. In some embodiments, the pulse mode is associated with lower power consumption or lower operating temperature. In some embodiments, the control signal includes one or more of a closed value or an open value. In some embodiments, the continuous mode includes operating the switch based on a control signal including a continuous mode control signal that includes a stable closed value. In some embodiments, the pulse mode includes operating the switch based on a control signal including a pulse mode control signal that includes a plurality of alternating open values and closed values.

[0006] According to another embodiment, a device is provided. In some embodiments, the device includes a magnetic core that includes (i) a core body and (ii) an air gap along the core body; a Hall effect sensor disposed in the air gap; an amplifier coupled to the Hall effect sensor; a driver coupled to the amplifier; a secondary winding that includes (i) a wire coil extending around the core body, (ii) a first end coupled to the driver, and (iii) a second end coupled to a sampling resistor; a switch configured to allow a feedback current from the driver to the secondary winding; and a controller unit coupled to the switch, the controller unit being configured to (i) receive a digital signal based on a sampling voltage associated with the sampling resistor, (ii) generate one or more control signals based on operating condition data that includes at least the digital signal and exceeds one or more thresholds, and (iii) transmit the one or more control signals to the switch.

[0007] In some embodiments, the device further includes a temperature sensor coupled to the controller unit, the temperature sensor being configured to: generate a data signal representative of the temperature of the sampling resistor; and transmit the data signal to the controller unit. In some embodiments, the operating condition data includes the data signal. In some embodiments, the switch is configured between the controller unit and the amplifier. In some embodiments, the switch is configured between the controller unit and the driver. In some embodiments, the switch is configured between the driver and the secondary winding.

[0008] According to another embodiment, a method for controlling a current sensor is provided. In some embodiments, the method includes receiving, by one or more processors, operating condition data associated with the current sensor; determining, by the one or more processors, that one or more thresholds have been exceeded based on the operating condition data; determining, by the one or more processors, an operating mode based on the one or more thresholds; determining, by the one or more processors, a control signal type based on the operating mode; and generating a control signal based on the control signal type, wherein (i) the control signal includes one of a continuous mode control signal or a pulse mode control signal, and (ii) is received by a switch associated with the current sensor and is used to configure the current sensor to operate in the operating mode.

[0009] In some embodiments, the operating condition data includes temperature data, a current measurement value, or a current frequency value. In some embodiments, the one or more thresholds include a primary current threshold, a temperature threshold, or a primary current frequency threshold. In some embodiments, the method further includes determining a pulse mode as an operating mode based on detecting a primary current above the primary current threshold or a temperature above the temperature threshold. In some embodiments, the method further includes determining a continuous mode as an operating mode based on the primary current frequency threshold taking precedence over one or more of the primary current threshold or the temperature threshold. In some embodiments, the one or more thresholds include a safety threshold that takes precedence over the primary current threshold, the temperature threshold, or the primary current frequency threshold. In some embodiments, the pulse mode control signal includes one or more of an adjustable phase or a duty cycle.

[0010] In the following detailed description and the accompanying drawings, the foregoing illustrative overview of the disclosure and other exemplary purposes and / or advantages, as well as the manner in which the exemplary purposes and / or advantages are achieved, are further explained. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The description of the illustrative embodiments may be read in conjunction with the accompanying drawings. It will be appreciated that, for simplicity and clarity of illustration, the elements illustrated in the figures are not necessarily drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements unless otherwise described. Embodiments incorporating the teachings of the disclosure are illustrated and described relative to the various figures presented herein, in which:

[0012] Figure 1 An example current sensor is depicted;

[0013] Figure 2 Example current sensors according to various embodiments of the present disclosure are depicted;

[0014] Figure 3A Example continuous mode control signals according to various embodiments of the present disclosure are depicted;

[0015] Figure 3B Example pulse mode control signals according to various embodiments of the present disclosure are depicted;

[0016] Figure 4A is a block diagram of an example current sensor device according to various embodiments of the present disclosure;

[0017] Figure 4B is a block diagram of an alternative example current sensor device according to various embodiments of the present disclosure;

[0018] Figure 4C is a block diagram of another alternative current sensor device according to various embodiments of the present disclosure;

[0019] Figure 5 is an example flowchart of an exemplary method for controlling a current sensor according to some example embodiments of the present disclosure;

[0020] Figure 6 depicts an example timing diagram for optimizing power consumption according to some example embodiments of the present disclosure.

[0021] Figure 7 depicts an example timing diagram for optimizing the current sensor temperature according to some example embodiments of the present disclosure.

[0022] Figure 8 depicts an example timing diagram for optimizing both power consumption and the current sensor temperature according to some example embodiments of the present disclosure. DETAILED DESCRIPTION

[0023] Some embodiments of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the present disclosure are shown. In fact, these disclosures may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numerals always refer to like elements.

[0024] As used herein, terms such as "front", "rear", "top", etc. are used for illustrative purposes in the examples provided below to describe the relative positioning of a particular component or a portion of a component. Further, in view of the present disclosure, as will be apparent to those of ordinary skill in the art, the terms "substantially" and "approximately" indicate that the referenced element or associated description is accurate within the applicable engineering tolerances.

[0025] As used herein, the term "comprising" means including but not limited to, and should be construed in the manner typically used in the patent context. The use of broader terms such as including, containing, and having should be understood to support narrower terms such as consisting of, consisting essentially of, and consisting substantially of.

[0026] The phrases "in one embodiment", "according to one embodiment", and the like generally mean that the particular feature, structure, or characteristic after such phrase may be included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0027] The term "example" or "exemplary" is used herein to mean "serving as an example, instance, or illustration". Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or superior to other implementations.

[0028] If the specification states that a component or feature "may", "can", "could", "should", "would", "preferably", "might", "typically", "optionally", "for example", "often", or "may" (or other such language) be included or have a characteristic, then the particular component or feature is not required to be included or have the characteristic. Such a component or feature may optionally be included in some embodiments, or it may be excluded.

[0029] A closed-loop current sensor may include a current measurement technique that provides electrical and galvanic isolation (e.g., no electrical contact) between a primary circuit (e.g., the circuit under test) and a sensor output for measuring the primary current of the primary circuit.

[0030] Figure 1 An example current sensor 100 is depicted. As Figure 1 depicted therein, current sensor 100 includes a closed-loop current sensor. Current sensor 100 includes a magnetic core 104 wound with a secondary winding 108. Current sensor 100 further includes a magnetic transducer 106 disposed in an air gap of magnetic core 104. Magnetic transducer 106 is coupled to an amplifier 110. Magnetic transducer 106 is configured to generate a voltage output (e.g., a Hall voltage) in the presence of a magnetic field around magnetic transducer 106 in the air gap. A magnetic field can be induced by inserting a conductor 102 carrying a primary current 112 inside magnetic core 104. The voltage output can be based on the magnetic flux density of the magnetic field around magnetic transducer 106, which is proportional to primary current 112.

[0031] The voltage output generated by magnetic transducer 106 can be amplified by amplifier 110 and converted into a feedback current 116. Secondary winding 108 is coupled to amplifier 110 at a first end of secondary winding 108 and receives feedback current 116 such that secondary winding 108 can generate a magnetic field opposite to the magnetic field associated with primary current 112, thereby generating a secondary current 114 at a second end of secondary winding 108 such that the following condition is created:

[0032] I P N P =I S N S Equation 1

[0033] where I P may represent primary current 112, I S may represent secondary current 114, NP can represent the number of primary windings associated with conductor 102, and N S can represent the number of secondary windings 108. Accordingly, the primary current 112 can be determined based on the derivative of the secondary current 114. A sampling resistor 118 including a known resistance value is coupled to the second end of the secondary winding 108. The secondary current 114 can be determined by receiving a sampling voltage 120 across the sampling resistor 118 and using Ohm's law (e.g., V = IR). The primary current 112 can be determined based on the secondary current 114 using Equation 1.

[0034] As a byproduct of receiving the secondary current 114, heat can be generated at the sampling resistor 118. According to Joule's law, the amount of heat generated at the sampling resistor 118 can be proportional to the square of the current in amperes and the resistance value. Accordingly, the greater the primary current 112, the greater the secondary current 114 and the associated heat output at the sampling resistor 118 can be. Thus, a greater secondary current 114 may require greater power consumption of the amplifier 110 to generate the feedback current 116. Overheating and high power consumption are generally parameters that are monitored and desired to be minimized in applications such as electric vehicles.

[0035] Various example embodiments of the present disclosure overcome such technical challenges and difficulties in current sensors and provide various technical advancements and improvements. According to various examples of the present disclosure, components of an example current sensor for improving current sensor performance are disclosed. In some embodiments, a closed-loop current sensor includes a switch configured to open or close a circuit of the closed-loop current sensor based on thermal and power consumption conditions and requirements. In some embodiments, the switch is configured to operate in a continuous mode or a pulse mode by, for example, a controller unit based on one or more thresholds and / or one or more optimization objectives. In some embodiments, the one or more thresholds include a primary current threshold, a temperature threshold, and a primary current frequency threshold. In some embodiments, the one or more optimization objectives include optimal power consumption regulation, optimal heating regulation, or overall regulation.

[0036] Figure 2Depicts an example current sensor 200 in accordance with various embodiments of the present disclosure. The current sensor 200 includes a closed-loop sensor that includes a magnetic transducer 206 (e.g., Hall effect sensor) in an air gap along the core of the magnetic core 204. The magnetic core 204 may include a ferromagnetic material such as nanocrystalline and permalloy materials (e.g., toroidal coil core). In some embodiments, the magnetic core 204 includes a torus, or commonly known as a doughnut or donut, having a shape that includes an annular portion and an internal void. The internal void of the magnetic core 204 may be configured to detect a primary current 212 carried by a conductor 202, and the primary current 212 may generate a magnetic flux detectable by the magnetic transducer 206.

[0037] The magnetic transducer 206 is coupled to an amplifier 210 (e.g., operational amplifier). A voltage output (e.g., Hall voltage) may be generated by the magnetic transducer 206 based on the magnetic flux detected by the magnetic transducer. The amplifier 210 may receive the voltage output from the magnetic transducer 216 and generate an amplified voltage signal that includes a feedback current 216. The feedback current 216 may be received at a first end of the secondary winding and driven through the secondary winding 208. The secondary winding 208 may include a wire coil that extends around the core of the magnetic core 204. In some embodiments, the secondary winding 208 includes a helical coil wound around the outside of the magnetic core 204. For example, the secondary winding 208 may include Ns number of turns around the magnetic core 204. The secondary winding 208 may include copper wire or any conductor suitable for conducting an electric current.

[0038] The feedback current 216 received by the secondary winding 208 may generate an opposing magnetic field that cancels the magnetic flux created by the primary current 212, thereby generating a secondary current 214 at a second end of the secondary winding 208 that is proportional to the primary current 212. A sampling resistor 218 (e.g., shunt resistor) is coupled to the second end of the secondary winding 208. The secondary current 214 may be determined by receiving a sampling voltage 220 across the sampling resistor 218 and converting the sampling voltage 220 into a digital signal that can be used to determine the value of the secondary current 214 based on the known resistance value of the sampling resistor 218. The secondary current 214 may be used to derive and determine the primary current 212.

[0039] The current sensor 200 further includes a switch 222 configured between the amplifier 210 and the secondary winding 208. The switch 222 can be configured to open or close (e.g., between the amplifier 210 and the secondary winding 208) a circuit path that allows the feedback current 216 to be transmitted from the amplifier 210 to the secondary winding 208 and thereby switch the operation (e.g., turn on or off) of the current sensor 200. According to various embodiments of the present disclosure, the switch 222 is configured to operate in a continuous mode or a pulse mode based on a control signal received from, for example, a controller unit. In some embodiments, the current sensor 200 is configured to operate in the continuous mode when a higher measurement accuracy of, for example, an alternating current (AC) associated with the sampled voltage 220 is desired. In some other embodiments, the current sensor 200 is configured to operate in the pulse mode when lower power consumption or a lower operating temperature is desired. In Figure 3A and Figure 3B Examples of continuous mode control signals and pulse mode control signals that can be transmitted to and received by the switch 222 are depicted.

[0040] Figure 3A An example continuous mode control signal according to various embodiments of the present disclosure is depicted. As Figure 3A depicted, a switch (e.g., switch 222) configured to switch the operation of a current sensor is controllable via a control signal that includes "closed" or "open" values associated with a closed switch state or an open switch state, respectively. According to various embodiments of the present disclosure, the closed switch state includes a switch in a closed position, thereby enabling the current sensor (e.g., current sensor 200) to be "turned on" or enabled (e.g., closing the circuit). Conversely, the open switch state includes the switch in an open position, thereby disabling the current sensor (e.g., opening the circuit). As Figure 3A and Figure 3B depicted, the "closed" value includes a non - zero value, and the "open" value includes a zero value. However, in other embodiments, the "closed" value can include a zero value, and the "open" value can include a non - zero value. The "closed" and "open" values can be arbitrarily designated and are not limited to the values disclosed herein.

[0041] As Figure 3A further depicted, the continuous mode control signal includes a stable "closed" value over a given time period. As Figure 3AAs depicted, a stable "closed" value can be received by the switch, during which the current sensor associated with the switch is directed to operate in continuous mode. During continuous mode, the stable "closed" value can allow the output from amplifier 210 (e.g., feedback current 216) to be transmitted to secondary winding 208 in a continuous manner, thereby allowing continuous operation and continuous readings of current sensor 200 to determine secondary current 214.

[0042] Figure 3B Depicts example pulse mode control signals in accordance with various embodiments of the present disclosure. As Figure 3B depicted, the pulse mode control signal includes alternating "closed" and "open" values over a given time period. As Figure 3B depicted, the alternating "closed" and "open" values can be received by the switch, during which the current sensor associated with the switch is directed to operate in pulse mode. During pulse mode, the switch associated with the current sensor transitions between open and closed positions and can allow the output from amplifier 210 (e.g., feedback current 216) to be periodically transmitted to secondary winding 208, thereby allowing periodic operation and periodic readings of current sensor 200 to determine secondary current 214.

[0043] Figure 4A Is a block diagram of an example current sensor device 400A in accordance with various embodiments of the present disclosure. Current sensor device 400A includes a magnetic core 402 and a Hall effect sensor 404 configured within an air gap along the core body of magnetic core 402. Inserting a conductor material carrying primary current 410 into the internal void defined by magnetic core 402 can cause a magnetic flux detectable by Hall effect sensor 404. Hall effect sensor 404 can generate a voltage output (e.g., Hall voltage) proportional to the intensity of the magnetic flux, the intensity of which is in turn proportional to the amount of primary current 410. The voltage output from Hall effect sensor 404 can be amplified by amplifier 406 to generate an amplified voltage used by driver 408 to drive a feedback current from the first end of secondary winding 412 through secondary winding 412 to the second end of secondary winding 412. Secondary winding 412 is wound around a portion of the magnetic core such that zero flux can be achieved when the feedback current is driven through secondary winding 412.

[0044] The sampling resistor 422 is configured to be in series with the second end of the secondary winding 412. A voltage signal can be taken from across the sampling resistor 422 (e.g., in parallel with the sampling resistor 422) and amplified by the amplifier 414. The amplified voltage from the amplifier 414 can be converted into a digital voltage signal suitable for input to the controller unit 418 by the analog-to-digital converter 416. The controller unit 418 can include one or more complex programmable logic devices (CPLDs), microprocessors, multi-core processors, co-processing entities, application-specific instruction-set processors (ASIPs), microcontrollers, and / or controllers.

[0045] Further, the controller unit 418 can be embodied as one or more other processing devices or circuits. The term circuit can refer to a fully hardware embodiment or a combination of hardware and a computer program product. Thus, the controller unit 418 can be embodied as an integrated circuit, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a programmable logic array (PLA), a hardware accelerator, other circuits, and / or the like.

[0046] Thus it will be appreciated that the controller unit 418 can be configured for a particular use or configured to execute instructions stored in a volatile or non-volatile medium or otherwise accessible to the controller unit 418. Accordingly, whether configured by hardware or a computer program product or a combination thereof, the controller unit 418, when configured accordingly, may be capable of performing the steps or operations according to embodiments of the present disclosure.

[0047] According to various embodiments of the present disclosure, the digital voltage signal includes the (sampled) voltage taken across the sampling resistor 422. Given the known value of the sampling resistor 422, the controller unit 418 can receive the digital voltage signal from the analog-to-digital converter 416 and determine the secondary current to determine the value of the primary current 410. Thus, the controller unit 418 can be configured to determine the primary current 410 based on the voltage taken across the sampling resistor 422.

[0048] The supply voltage switch 420A is coupled between the amplifier 406 and the controller unit 418. In some embodiments, the controller unit 418 can configure the operation mode of the current sensor device 400A by transmitting a control signal to the supply voltage switch 420A. The supply voltage switch 420A is coupled to the supply voltage of the amplifier 406 and can be controlled by the controller unit 418 (e.g., via continuous mode and pulse mode control signals) to turn on and off the amplifier 406.

[0049] Figure 4B is a block diagram of an alternative example current sensor device 400B according to various embodiments of the present disclosure. As Figure 4BAs depicted, supply voltage switch 420B is coupled between driver 408 and controller unit 418 for configuring the operation mode of current sensor device 400B. In some embodiments, controller unit 418 may configure the operation mode of current sensor device 400B by transmitting a control signal to supply voltage switch 420B. Supply voltage switch 420B is coupled to the supply voltage of driver 408 and may be controlled by controller unit 418 (e.g., via continuous mode and pulse mode control signals) to turn on and off driver 408.

[0050] Figure 4C is a block diagram of another alternative current sensor device 400C according to various embodiments of the present disclosure. As Figure 4C depicted, analog switch 420C is configured between driver 408 and secondary winding 412 for configuring the operation mode of current sensor device 400C. In some embodiments, controller unit 418 may configure the operation mode of current sensor device 400C by transmitting a control signal to analog switch 420C. Analog switch 420C may be controlled by controller unit 418 (e.g., via continuous mode and pulse mode control signals) to open and close the path between driver 408 and secondary winding 412, which is used to drive a feedback current to secondary winding 412.

[0051] In some embodiments, controller unit 418 may determine the operation mode to configure any one of current sensor devices 400A, 400B, and 400C based on a component temperature such as sampling resistor 422. As Figure 4A 、 Figure 4B and Figure 4C further depicted, current sensor devices 400A, 400B, and 400C further include temperature sensor 424. Temperature sensor 424 may be configured to monitor the temperature of sampling resistor 422. Temperature sensor 424 may generate a data signal representative of the temperature of sampling resistor 422. The signal generated by temperature sensor 424 may be transmitted to and received by controller unit 418 to determine whether the temperature of sampling resistor 422 exceeds a temperature threshold. In some example embodiments, controller unit 418 may configure current sensor devices 400A, 400B, and 400C to operate in pulse mode based on a determination that sampling resistor 422 is operating at a temperature above the temperature threshold.

[0052] According to various embodiments of the present disclosure, one or more of the current sensor devices 400A, 400B, or 400C operate in continuous mode or pulse mode based on one or more operating thresholds. In some embodiments, if the primary current determined (based on the determination of the secondary current and the derivation from the secondary current) by one or more of the current sensor devices 400A, 400B, or 400C is higher than a defined threshold, one or more of the current sensor devices 400A, 400B, or 400C are configured by a processing device (such as the controller unit 418) to operate in pulse mode to reduce power consumption. In some other embodiments, if the operating temperature (e.g., determined using the temperature sensor 424) is higher than a temperature threshold, one or more of the current sensor devices 400A, 400B, or 400C are configured by the processing device to operate in pulse mode to reduce heating. In some additional embodiments, if the frequency of the primary current including AC current is determined by one or more of the current sensor devices 400A, 400B, or 400C to be higher than a threshold, one or more of the current sensor devices 400A, 400B, or 400C are configured by the processing device to operate in continuous mode, thereby providing a sufficient sampling rate to ensure an accurate determination of the primary current.

[0053] Now refer to Figure 5 , an example flowchart of an exemplary method for controlling a current sensor according to some example embodiments of the present disclosure is illustrated. Note that each block of the flowchart and combinations of blocks in the flowchart can be implemented by various components, such as hardware, firmware, circuitry, and / or other devices associated with the execution of software including one or more computer program instructions. For example, Figure 5 One or more of the steps / operations described in

[0054] In Figure 5In [the example], the example method 500 can be performed by a computing device associated with a current sensor (e.g., as illustrated and described herein). At step 502, operating condition data associated with the current sensor is received. In some embodiments, the operating condition data includes temperature data, a current measurement value, or a current frequency value. The temperature data can be associated with the temperature of one or more components within the current sensor, such as a sampling resistor from which a voltage reading is obtained (e.g., to determine a secondary current and derive / determine a primary current based on the secondary current). The current measurement value can be associated with the determined secondary current or the derived / determined primary current. The current frequency value can be associated with the frequency of the primary current including an AC current to be derived / determined (e.g., the rate at which the current changes direction per second).

[0055] In some embodiments, after step 502, the example method proceeds to step 504, where the operating condition data is analyzed to determine or detect whether one or more thresholds have been exceeded. In some example embodiments, the one or more thresholds can include a primary current threshold TH_IP, a temperature threshold TH_temp, or a primary current frequency threshold TH_freq.

[0056] In some embodiments, after step 504, if the thresholds are not exceeded, the operating condition data can continue to be received and monitored via steps 502 and 504 for one or more thresholds being exceeded.

[0057] In some embodiments, after step 504, if one or more thresholds have been exceeded, the example method proceeds to step 506, where an operating mode is determined based on the one or more exceeded thresholds. For example, if the primary current determined by the current sensor is higher than the primary current threshold (e.g., 600 A), the current sensor can be configured to enter a pulse mode to reduce power consumption. In another example, if the temperature of the current sensor (or its components) is higher than the temperature threshold (e.g., 158°F or 70°C), the current sensor can be configured to enter a pulse mode to reduce heating. In yet another example, if the primary current frequency (e.g., the frequency of the primary current including an AC current) is higher than the frequency threshold (e.g., 400 Hz), the current sensor can be configured to enter a continuous mode to be able to capture the primary current operating at the primary current frequency, thereby providing sensing accuracy.

[0058] In some embodiments, determining the operating mode further includes determining an optimization objective. The optimization objective can be determined for instances in which more than one threshold is exceeded. In some embodiments, one or more of the exceeded thresholds can be prioritized for which operating mode the current sensor should operate in. For example, the current sensor can be configured in a pulsed mode for reducing power consumption and current sensor temperature. However, measurement accuracy can take precedence over power consumption and / or current sensor temperature. That is, even though the power consumption and / or current sensor temperature thresholds are exceeded, the current sensor can be configured in a continuous mode based on the primary current frequency exceeding a frequency threshold.

[0059] In some other embodiments, the one or more thresholds further include one or more safety thresholds. The safety threshold can include a threshold that takes precedence over non-safety thresholds. For example, a primary current threshold TH_IP, a temperature threshold TH_temp, or a primary current frequency threshold TH_freq can include non-safety thresholds. In some example embodiments, the safety threshold includes a safety temperature threshold or an overcurrent threshold that takes precedence over the primary current frequency threshold TH_freq. Accordingly, in the event of exceeding the safety temperature threshold or the overcurrent threshold, the current sensor can be configured in a pulsed mode or a mode in which the switch state of the current sensor is configured in an open position.

[0060] Figure 6 An example timing diagram for optimizing power consumption in accordance with some example embodiments of the present disclosure is depicted. Optimizing power consumption can include monitoring the determined primary current and primary current frequency. Optimizing power consumption can further include configuring the current sensor to operate in a pulsed mode or a continuous mode based on the determined primary current and / or primary current frequency exceeding or not exceeding a primary current threshold TH_IP and / or a primary current frequency threshold TH_freq, respectively.

[0061] As Figure 6 depicted, based on (i) the determined primary current not exceeding the primary current threshold TH_IP and (ii) the primary current frequency not exceeding the primary current frequency threshold TH_freq, the current sensor is configured in a continuous mode (e.g., before T0, T1 - T2, and after T5). In the event that only the determined primary current exceeds the primary current threshold TH_IP, the current sensor can be configured to operate in a pulsed mode (e.g., T0 - T1, T2 - T3, and T4 - T5) to reduce power consumption. When the primary current frequency exceeds the primary current frequency threshold TH_freq, the current sensor can be configured to operate in a continuous mode (e.g., regardless of whether the determined primary current exceeds the primary current threshold TH_IP) such that the current sensor can capture the primary current operating at the primary current frequency (e.g., T3 - T4).

[0062] Figure 7 Depicts an example timing diagram for optimizing the current sensor temperature according to some example embodiments of the present disclosure. Optimizing the current sensor temperature may include monitoring the current sensor temperature and the primary current frequency. Optimizing the current sensor temperature may further include configuring the current sensor to operate in a pulsed mode or a continuous mode based on whether the current sensor temperature and / or the primary current frequency respectively exceed or do not exceed a temperature threshold TH_temp and / or a primary current frequency threshold TH_freq.

[0063] As Figure 7 depicted, based on (i) the current sensor temperature not exceeding the temperature threshold TH_temp and (ii) the primary current frequency not exceeding the primary current frequency threshold TH_freq, the current sensor may be configured to operate in a continuous mode (e.g., before T0, between T1 - T2, and after T5). In the event that only the current sensor temperature is above the temperature threshold TH_temp, the current sensor may be configured to operate in a pulsed mode (e.g., between T0 - T1, T2 - T3, and T4 - T5) to reduce heating. When the primary current frequency exceeds the primary current frequency threshold TH_freq, the current sensor may be configured to operate in a continuous mode (e.g., regardless of whether the current sensor temperature exceeds the temperature threshold TH_temp), such that the current sensor can capture the primary current operating at the primary current frequency (e.g., between T3 - T4).

[0064] Figure 8 Depicts an example timing diagram for optimizing power consumption and current sensor temperature according to some example embodiments of the present disclosure. Simultaneously optimizing power consumption and current sensor temperature may include monitoring the determined primary current, the current sensor temperature, and the primary current frequency. Optimization for both power consumption and current sensor temperature may further include configuring the current sensor to operate in a pulsed mode or a continuous mode based on whether one or more of the determined primary current, the current sensor temperature, and / or the primary current frequency respectively exceed or do not exceed a primary current threshold TH_IP, a temperature threshold TH_temp, and / or a primary current frequency threshold TH_freq.

[0065] As Figure 8As depicted, based on (i) the determined primary current not exceeding the primary current threshold TH_IP, (ii) the current sensor temperature not exceeding the temperature threshold TH_temp, and (iii) the primary current frequency not exceeding the primary current frequency threshold TH_freq, the current sensor is configured to operate in continuous mode (e.g., before T0, T1 - T2, T3 - T4, and after T7). Based on one or more of (i) the determined primary current exceeding the primary current threshold TH_IP or (ii) the current sensor temperature exceeding the temperature threshold TH_temp, the current sensor is configured to operate in pulse mode. When the primary current frequency exceeds the primary current frequency threshold TH_freq, the current sensor can be configured to operate in continuous mode (e.g., regardless of whether the determined primary current exceeds the primary current threshold TH_IP or the current sensor temperature exceeds the temperature threshold TH_temp), such that the current sensor can capture the primary current operating at the primary current frequency (e.g., T5 - T6).

[0066] Return to Figure 5 , in some embodiments, after step 506, the exemplary method proceeds to step 508, where the type of control signal is determined based on the determined operating mode. According to various embodiments of the present disclosure, the type of control signal can be determined as a continuous mode control signal or a pulse mode control signal. For example, a continuous mode control signal can be determined for continuous mode, and a pulse mode control signal can be determined for pulse mode.

[0067] In some embodiments, after step 508, if the determined type of control signal is a continuous mode control signal, the exemplary method proceeds to step 510, where a continuous mode control signal is generated. In some embodiments, the continuous mode control signal includes a stable "closed" value over a given time period. The generated continuous mode control signal can be received by a switch and used to control the operation of the current sensor to operate continuously and continuously obtain readings for determining the primary current. In some embodiments, after step 510, the exemplary method proceeds to step 502.

[0068] In some embodiments, after step 508, if the determined control signal type is a pulse mode control signal, the exemplary method proceeds to step 512, where a pulse mode control signal is generated. In some embodiments, the pulse mode control signal includes alternating "closed" and "open" values over a given time period. The generated pulse mode control signal can be received by a switch and used to control the operation of a current sensor to operate at periodic time intervals and obtain readings to determine the primary current during the periodic time intervals. In some embodiments, the phase and / or duty cycle associated with the pulse mode control signal can be adjusted to achieve a desired optimization goal (e.g., lower power consumption, lower heating, or both) and a desired sensing accuracy. In some embodiments, after step 512, the exemplary method proceeds to step 502.

[0069] It should be understood that the present disclosure is not limited to the particular embodiments disclosed, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a general and descriptive sense only and not for purposes of limitation, unless otherwise described.

Claims

1. A current sensor, comprising: A magnetic core, comprising (i) a core body and (ii) an air gap along the core body; A magnetic transducer disposed in the air gap; An amplifier coupled to the magnetic transducer; A secondary winding including a wire coil extending around the core body; And A switch coupled between the amplifier and the secondary winding, the switch being configured to open or close a circuit path between the amplifier and the secondary winding by operating in a continuous mode or a pulse mode based on a control signal.

2. The current sensor according to claim 1, wherein the amplifier is configured to: Receive an output voltage from the magnetic transducer; and Generate an amplified voltage including a feedback current.

3. The current sensor according to claim 1, wherein the switch is configured to allow the feedback current to flow from the amplifier to the secondary winding via the circuit path.

4. The current sensor according to claim 1, wherein the continuous mode is associated with higher measurement accuracy.

5. The current sensor according to claim 1, wherein the pulse mode is associated with lower power consumption or lower operating temperature.

6. The current sensor according to claim 1, wherein the control signal includes one or more of a closed value or an open value.

7. The current sensor according to claim 1, wherein the continuous mode includes operating the switch based on a control signal including a continuous mode control signal, the continuous mode control signal including a stable closed value.

8. The current sensor according to claim 1, wherein the pulse mode includes operating the switch based on a control signal including a pulse mode control signal, the pulse mode control signal including a plurality of alternating open values and closed values.

9. A device, comprising: A magnetic core, comprising (i) a core body and (ii) an air gap along the core body; A Hall effect sensor disposed in the air gap; An amplifier coupled to the Hall effect sensor; A driver coupled to the amplifier; A secondary winding, comprising (i) a wire coil extending around the core body, (ii) a first end coupled to the driver, and (iii) a second end coupled to a sampling resistor; A switch configured to allow a feedback current to flow from the driver to the secondary winding; And A controller unit coupled to the switch, the controller unit being configured to (i) receive a digital signal based on a sampling voltage associated with the sampling resistor, (ii) generate one or more control signals based on operating condition data including at least the digital signal exceeding one or more thresholds, and (iii) transmit the one or more control signals to the switch.

10. The device according to claim 9, further comprising a temperature sensor coupled to the controller unit, the temperature sensor being configured to: Generate a data signal representative of the temperature of the sampling resistor; and Transmit the data signal to the controller unit.

11. The device according to claim 10, wherein the operating condition data includes the data signal.

12. The device according to claim 9, wherein the switch is disposed between the controller unit and the amplifier.

13. The device according to claim 9, wherein the switch is configured between the controller unit and the driver.

14. The device according to claim 9, wherein the switch is configured between the driver and the secondary winding.

15. A method for controlling a current sensor, the method comprising: receiving, by one or more processors, operating condition data associated with the current sensor; determining, by the one or more processors, based on the operating condition data that one or more thresholds have been exceeded; determining, by the one or more processors, an operating mode based on the one or more thresholds; determining, by the one or more processors, a control signal type based on the operating mode; and generating a control signal based on the control signal type, wherein (i) the control signal includes one of a continuous mode control signal or a pulse mode control signal, and (ii) is received by a switch associated with the current sensor and is used to configure the current sensor to operate in the operating mode.

16. The method according to claim 15, wherein the operating condition data includes temperature data, current measurement values, or current frequency values.

17. The method according to claim 15, wherein the one or more thresholds include a primary current threshold, a temperature threshold, or a primary current frequency threshold.

18. The method according to claim 17, further comprising determining a pulse mode as the operating mode based on detecting a primary current higher than the primary current threshold or a temperature higher than the temperature threshold.

19. The method according to claim 17, further comprising determining a continuous mode as the operating mode based on the primary current frequency threshold taking precedence over one or more of the primary current threshold or the temperature threshold.

20. The method according to claim 17, wherein the one or more thresholds include a safety threshold that takes precedence over the primary current threshold, the temperature threshold, or the primary current frequency threshold.

21. The method according to claim 15, wherein the pulse mode control signal includes one or more of an adjustable phase or duty cycle.

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