A coreless current sensor and motor controller

Abstract

This invention belongs to the field of vehicle system current detection technology, and provides a coreless current sensor and a motor controller. The coreless current sensor of this invention includes a current-carrying conductor and a reinforcing member. The current-carrying conductor has a detection section with a detection hole for placing a chip. At least one side of the detection section, perpendicular to the current direction of the current-carrying conductor, has a magnetizing notch recessed towards the detection hole. The reinforcing member is disposed at the magnetizing notch and is made of an insulating material with a relative permeability of 1. This invention improves the overall structural strength of the current-carrying conductor and also enhances the detection accuracy of the chip.

Description

Technical Field

[0001] This utility model relates to the field of vehicle system current detection technology, and in particular to a coreless current sensor and motor controller. Background Technology

[0002] Current sensors are among the most important sensors in inverter control systems. By sensing the current on the motor phase lines, they provide key parameters for achieving torque closed-loop control. With increasing automotive automation, accurate and low-latency current detection is crucial for system control, reliability, and safety. To meet these requirements, current sensors need to be fast, accurate, and adaptable to changes in magnetic fields and installation deviations.

[0003] In existing technologies, Hall effect current sensors are commonly used to detect the phase current of a motor. Conventional Hall effect current sensors have a shielding cover, which enhances the magnetic field, but this also results in a larger footprint, increasing the overall vehicle weight and reducing valuable driving range. To overcome this drawback, a coreless current sensor can be used.

[0004] To collect the magnetic field surrounding the copper busbar when current flows through it, coreless current sensors require holes to be drilled in the busbar, which reduces its structural strength. During vehicle operation, vibrations are unavoidable; prolonged vibrations can cause the copper busbar to twist and break, shortening its lifespan. Furthermore, in the event of busbar failure, the current sensor's detection is inaccurate, leading to inverter failure and even serious driving safety issues.

[0005] Therefore, a new solution is needed to address the aforementioned technical problems. Utility Model Content

[0006] In view of the shortcomings of the prior art described above, the purpose of this utility model is to provide a coreless current sensor and motor controller to solve the problem of easy damage to copper busbars in the prior art.

[0007] To achieve the above and other related objectives, this utility model provides a coreless current sensor, specifically configured as follows: it includes a current-carrying conductor and a reinforcing member. The current-carrying conductor has a detection section, on which a detection hole for placing a chip is formed. At least one side of the detection section perpendicular to the current direction of the current-carrying conductor has a magnetizing notch recessed toward the detection hole. The reinforcing member is disposed at the magnetizing notch, and the reinforcing member is made of an insulating material with a relative permeability of 1.

[0008] Optionally, the reinforcing member is fitted onto the detection section, and the detection hole is exposed outside the reinforcing member.

[0009] Optionally, the chip is inserted into the detection hole, and the circumferential sidewall of the chip is spaced apart from the inner sidewall of the detection hole.

[0010] Optionally, the reinforcing member wraps around the inner wall of the detection hole, and a positioning structure is provided on the reinforcing member located inside the detection hole to position the chip inside the detection hole.

[0011] Optionally, the positioning structure is configured as a reinforcing rib extending toward the interior of the detection hole, with one end of the reinforcing rib abutting against the chip.

[0012] Optionally, the detection hole is provided with a plurality of reinforcing ribs in the circumferential direction, and the accommodating space formed by the plurality of reinforcing ribs matches the outer contour of the chip.

[0013] Optionally, the chip is fixed to the reinforcing rib.

[0014] Optionally, the reinforcing member is clamped at the magnetizing gap and completely covers the magnetizing gap; or the reinforcing member fills the magnetizing gap.

[0015] Optionally, the magnetizing notches are provided on both sides of the detection section perpendicular to the direction of the current; the detection hole is biased towards either of the magnetizing notches, or is located in the middle between two magnetizing notches.

[0016] This utility model also provides a motor controller, which includes any of the above-described coreless current sensors.

[0017] As described above, the coreless current sensor and motor controller of this utility model have the following beneficial effects:

[0018] A detection section is provided on the current-carrying conductor, and a detection hole for placing a chip is provided on the detection section. In order to improve the magnetic field strength around the detection hole, a magnetizing notch is provided on at least one side of the detection section perpendicular to the current direction of the current-carrying conductor, which is recessed toward the detection hole. In order to improve the overall strength of the current-carrying conductor, a reinforcing member is provided at the magnetizing notch, thereby improving the structural strength of the detection section. Moreover, the aforementioned reinforcing member is made of an insulating material with a relative permeability of 1, so that the reinforcing member improves the structural strength of the current-carrying conductor without affecting the magnetizing effect of the magnetizing notch, thereby helping to improve the detection accuracy of the chip located in the detection hole. Attached Figure Description

[0019] Figure 1 The diagram shows a structural schematic of a coreless current sensor according to an embodiment of the present invention.

[0020] Figure 2 The diagram shown is a structural schematic of a current-carrying conductor according to an embodiment of the present invention.

[0021] Figure 3 The diagram shown is a structural schematic of a current-carrying conductor and a reinforcing member according to an embodiment of the present invention.

[0022] Figure 4 The diagram shows a structural schematic of a current-carrying conductor and a reinforcing member according to another embodiment of the present invention.

[0023] Figure 5 Displayed as Figure 1 A schematic diagram of the structure of part A in the middle.

[0024] Explanation of reference numerals in the attached figures

[0025] 1-Current-carrying conductor; 11-Detection hole; 12-Magnetic notch;

[0026] 2-Reinforcing member; 21-Reinforcing rib;

[0027] 3-Chip. Detailed Implementation

[0028] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model.

[0029] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of this utility model. Therefore, the illustrations only show components relevant to this utility model and are not drawn according to the actual number, shape, and size of the components in implementation. In actual implementation, the shape, quantity, and proportion of each component can be arbitrarily changed, and the component layout may be more complex. The structures, proportions, and sizes shown in the accompanying drawings are only for illustrative purposes to aid those skilled in the art and are not intended to limit the implementation conditions of this utility model. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effects and objectives of this utility model, should still fall within the scope of the technical content disclosed in this utility model. Furthermore, terms such as "upper," "lower," "left," "right," "middle," and "one" used in this specification are only for clarity of description and are not intended to limit the scope of implementation of this utility model. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of implementation of this utility model.

[0030] like Figure 1 and Figure 2As shown, some embodiments of this utility model provide a coreless current sensor, including a current-carrying conductor 1 and a reinforcing member 2.

[0031] The current-carrying conductor 1 has a detection section with a detection hole 11 for placing the chip 3. When current flows through the current-carrying conductor 1, the chip 3 detects the magnetic field of the detection section. To increase the magnetic field strength of the detection section and thus improve the detection accuracy of the chip 3, a magnetizing notch 12 is provided on at least one side of the detection section perpendicular to the current direction of the current-carrying conductor 1. The magnetizing notch 12 may be located on the left side of the current direction of the detection section, or on the right side of the current direction of the detection section, or on both the left and right sides of the current direction of the detection section, and the magnetizing notch 12 is recessed from the side wall of the current-carrying conductor 1 toward the detection hole 11.

[0032] While the above-mentioned arrangement enhances the magnetic field of the detection section, it reduces the structural strength of the detection section. To improve the structural strength of the detection section, a reinforcing member 2 is provided on the current-carrying conductor 1. This reinforcing member 2 is located at the magnetizing notch 12, thereby enhancing the structural strength of the detection section and thus improving the overall structural strength of the current-carrying conductor 1.

[0033] Furthermore, the reinforcing member 2 is made of an insulating material with a relative permeability of 1, which will not affect the magnetizing effect of the magnetizing notch 12. For example, the reinforcing member 2 is made of a material with an electrical conductivity of 0 and a relative permeability of 1, including but not limited to materials such as polytetrafluoroethylene and polyamide.

[0034] For example, the current-carrying conductor 1 may include, but is not limited to, a copper busbar.

[0035] In one example, magnetizing notches 12 are provided on both sides of the detection segment perpendicular to the current direction. This helps to increase the magnetic field strength of the detection segment, thereby improving the detection accuracy of the chip 3. The shape and size of the magnetizing notches 12 are adaptively set according to the actual needs of the magnetic field of the detection segment. It should be noted that the shape and size of the two magnetizing notches 12 can be set to be the same.

[0036] The detection hole 11 set on the current-carrying conductor 1 can be set to be biased towards any one of the magnetizing gaps 12, or biased towards the left side of the current direction, or biased towards the right side of the current direction; it can also be set in the middle position between two magnetizing gaps 12. The specific setting position can be adapted to actual needs.

[0037] like Figure 3 and Figure 4As shown, in some embodiments, the reinforcing member 2 can be configured as a C-shaped structure so that it can be clamped at the magnetizing gap and completely cover the magnetizing gap, thereby improving the structural strength of the current-carrying conductor 1. Alternatively, the reinforcing member 2 can be configured as a filler block that completely fills the magnetizing gap 12, thereby improving the structural strength of the current-carrying conductor 1. Alternatively, the reinforcing member 2 can be configured as a connecting rib structure, with its two ends respectively connected to both sides of the magnetizing gap 12 along the current direction of the current-carrying conductor 1, thereby improving the structural strength of the current-carrying conductor 1.

[0038] like Figure 1 and Figure 5 As shown, in some other embodiments, the reinforcing member 2 is sleeved on the detection section, that is, the circumference of the detection section is wrapped by the reinforcing member 2, the magnetizing gap 12 is filled by the reinforcing member 2, which serves to support the magnetizing gap 12, and the wall thickness of the remaining parts of the detection section is thickened, thereby improving the structural strength of the detection section. It should be noted that the detection hole 11 is exposed outside the reinforcing member 2 to facilitate the installation of the chip 3.

[0039] In one example, the reinforcing member 2 can be integrally molded with the current conductor 1 by injection molding, or it can be connected to the current conductor 1 by snap-fitting, or other feasible methods.

[0040] In some embodiments, the chip 3 is inserted into the detection hole 11, and the circumferential sidewall of the chip 3 is spaced apart from the inner sidewall of the detection hole 11, so that the chip 3 and the current-carrying conductor 1 are isolated from each other by high and low voltage, thereby achieving the insulation requirement between the two. For example, a circuit board is soldered to the side of the chip 3 away from the current-carrying conductor 1 via pins.

[0041] It should be noted that the chip 3 used in this invention is a coreless Hall chip, which is a sensor chip that uses the Hall effect for current detection. Compared with traditional magnetic core Hall sensors, it does not require a magnetic core, thus avoiding the influence of factors such as magnetic core saturation / hysteresis loss on the measurement results, and has higher response speed and accuracy. A coreless Hall chip typically consists of two adjacent Hall elements, which measure the magnetic fields generated in two directions when current flows through the current-carrying conductor 1, and then take the difference between the magnetic field signals in the two directions to obtain the current signal.

[0042] In some embodiments, the inner wall of the detection hole 11 is exposed outside the reinforcing member 2, meaning the reinforcing member 2 does not cover the inner wall of the detection hole 11. In other embodiments, the reinforcing member 2 covers the inner wall of the detection hole 11. To further improve the detection accuracy of the chip 3, a positioning structure is provided on the reinforcing member 2 located inside the detection hole 11 to position the chip 3 within the detection hole 11, preventing the chip 3 from shifting relative to the current-carrying conductor 1 during vehicle movement.

[0043] In some embodiments, the positioning structure is configured as a reinforcing rib 21 extending into the detection hole 11. The end of the reinforcing rib 21 facing the chip 3 abuts against the chip 3 to position the chip 3 circumferentially near the inner wall of the detection hole 11. Simultaneously, the reinforcing rib 21 allows for point contact between the reinforcing rib 21 and the chip 3, preventing damage to the chip 3 when using surface contact positioning if the circumferential sidewall of the chip 3 is uneven.

[0044] In one example, a reinforcing rib 21 is provided on one inner sidewall of the detection hole 11. The number of reinforcing ribs 21 can be one, two, or more. The reinforcing rib 21 abuts against the chip 3, so that the chip 3 abuts against the reinforcing member 2 on the inner sidewall of the detection hole 11 away from the reinforcing rib 21, thereby achieving positioning of the chip 3. In another example, reinforcing ribs 21 are provided on any two or three inner sidewalls of the detection hole 11. The number of reinforcing ribs 21 on one side can be one, two, or more. The reinforcing rib 21 abuts against the chip 3, so that the chip 3 is abutted against the reinforcing member 2 on the inner sidewall of the detection hole 11 without reinforcing ribs 21, thereby achieving positioning of the chip 3. In yet another example, multiple reinforcing ribs 21 are provided circumferentially in the detection hole 11, that is, each sidewall of the detection hole 11 is provided with a reinforcing rib 21. The receiving space formed by the multiple reinforcing ribs 21 matches the outer contour of the chip 3, so that each reinforcing rib 21 abuts against the chip 3, achieving positioning of the chip 3.

[0045] In some embodiments, to prevent the chip 3 from shifting along the opening direction of the detection hole 11, the chip 3 can be fixedly mounted on the reinforcing rib 21 by dispensing adhesive.

[0046] In summary, the present invention provides a coreless current sensor with a detection section on a current-carrying conductor. This detection section has a detection hole for placing a chip. To increase the circumferential magnetic field strength of the detection hole, a magnetizing notch recessed towards the detection hole is formed on at least one side of the detection section perpendicular to the current direction of the current-carrying conductor. To improve the overall strength of the current-carrying conductor, a reinforcing member is provided at the magnetizing notch, thereby improving the structural strength of the detection section. Furthermore, the reinforcing member is made of an insulating material with a relative permeability of 1, ensuring that while improving the structural strength of the current-carrying conductor, it does not affect the magnetizing effect of the magnetizing notch, thus improving the detection accuracy of the chip located in the detection hole.

[0047] Some embodiments of this utility model also provide a motor controller, which includes the aforementioned coreless current sensor.

[0048] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. A coreless current sensor characterized by, include: A current-carrying conductor has a detection section, on which a detection hole for placing a chip is formed, and on at least one side of the detection section perpendicular to the current direction of the current-carrying conductor, a magnetizing notch is formed that is recessed toward the detection hole. A reinforcing member is disposed at the magnetizing notch, and the reinforcing member is made of an insulating material with a relative permeability of 1.

2. The coreless current sensor of claim 1, wherein: The reinforcing member is fitted onto the detection section, and the detection hole is exposed on the reinforcing member.

3. The coreless current sensor of claim 2, wherein: The chip is inserted into the detection hole, and the circumferential sidewall of the chip is spaced apart from the inner sidewall of the detection hole.

4. The coreless current sensor according to claim 3, characterized in that: The reinforcing member wraps around the inner wall of the detection hole, and a positioning structure is provided on the reinforcing member located inside the detection hole to position the chip inside the detection hole.

5. The coreless current sensor according to claim 4, characterized in that: The positioning structure is configured as a reinforcing rib extending toward the interior of the detection hole, with one end of the reinforcing rib abutting against the chip.

6. The coreless current sensor according to claim 5, characterized in that: The detection hole is provided with a plurality of reinforcing ribs in the circumferential direction, and the accommodating space formed by the plurality of reinforcing ribs matches the outer contour of the chip.

7. The coreless current sensor according to claim 5, characterized in that: The chip is fixed to the reinforcing rib.

8. The coreless current sensor according to claim 1, characterized in that: The reinforcing member is clamped at the magnetizing gap and completely covers the magnetizing gap; or the reinforcing member fills the magnetizing gap.

9. The coreless current sensor according to any one of claims 1-8, characterized in that: The detection section has magnetizing notches on both sides perpendicular to the direction of the current; the detection hole is biased toward either of the magnetizing notches, or is located in the middle between two magnetizing notches.

10. A motor controller, characterized in that: Including the coreless current sensor described in any one of claims 1-9 above.

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