Current sensor

Abstract

This application relates to a current sensor, including a mounting bracket, multiple coils, a magnetic ring, and a Hall element. The mounting bracket includes multiple supports arranged in a ring around each other, with at least one support being longer than another. Multiple coils are wound one-to-one around the supports, with the number of turns of each coil being positively correlated with the length of its support. The magnetic ring has an air gap and is positioned within the supports along their extension direction. At least one support has a socket, the position of which corresponds to the position of the air gap. The Hall element is inserted into the support through the socket and located within the air gap. This current sensor improves detection accuracy while increasing the compensation magnetic field.

Description

Technical Field

[0001] This application relates to the field of current sensor technology, and in particular to a current sensor. Background Technology

[0002] Current sensors are used to convert large primary currents into smaller secondary currents through a certain transformation ratio, and can be used for circuit protection and measurement.

[0003] However, in related technologies, the compensating magnetic field generated by the coil in the current sensor is small, which is difficult to meet the needs of situations where the measured current is large. While winding a coil with more turns can increase the compensating magnetic field, it will result in poor magnetic field uniformity, leading to low measurement accuracy. Utility Model Content

[0004] Therefore, it is necessary to provide a current sensor to solve the problem of how to increase the compensation magnetic field while improving the detection accuracy.

[0005] This application provides a current sensor, including:

[0006] The mounting frame includes multiple supports arranged in a ring around each other, and the length of at least one of the supports is greater than the length of another support.

[0007] Multiple coils are wound one-to-one on multiple brackets, and the number of turns of each coil is positively correlated with the length of the bracket it is located on;

[0008] A magnetic ring having an air gap is provided in a plurality of brackets along the extension direction of the plurality of brackets. At least one bracket is provided with an insertion hole, the position of which corresponds to the position of the air gap.

[0009] A Hall element is inserted into the bracket through the socket and located within the air gap.

[0010] In one embodiment, each of the coils is uniformly wound on the corresponding bracket, and the number of turns is equal.

[0011] In one embodiment, the magnetic ring includes a first magnetic core, a second magnetic core, and a third magnetic core, wherein the first magnetic core, the second magnetic core, and the third magnetic core are arranged in a rectangular ring.

[0012] The first magnetic core is in the shape of a straight bar. One end of the second magnetic core and one end of the third magnetic core are respectively connected to the two ends of the first magnetic core. The other ends of the second magnetic core and the other ends of the third magnetic core are spaced apart to form the air gap.

[0013] In one embodiment, both the second magnetic core and the third magnetic core include two sub-sections that are perpendicularly connected to each other; the mounting bracket includes four brackets, namely a first bracket, a second bracket, a third bracket, and a fourth bracket;

[0014] The first magnetic core is inserted through the first bracket, one of the sub-parts of the second magnetic core is inserted through the second bracket, the other sub-part of the second magnetic core is inserted through the third bracket, one of the sub-parts of the third magnetic core is inserted through the third bracket, and the other sub-part of the third magnetic core is inserted through the fourth bracket, wherein the third bracket is provided with the insertion hole.

[0015] In one embodiment, the length of the first support is equal to the length of the third support; the length of the second support is equal to the length of the fourth support.

[0016] In one embodiment, the length of the first support is greater than the length of the second support.

[0017] In one embodiment, the first bracket is provided with a first reinforcing block, and the first reinforcing block is provided with a first wire passage groove. A portion of the coil wound on the first bracket is located on one side of the first reinforcing block, and the other portion passes through the first wire passage groove to the other side of the first reinforcing block.

[0018] In one embodiment, the socket is disposed on the first reinforcing block, the current sensor further includes a circuit board, the Hall element is disposed on the circuit board, and the first reinforcing block is provided with a first support portion, which abuts against the circuit board.

[0019] In one embodiment, the third bracket is provided with a second reinforcing block, and the second reinforcing block is provided with a second wire passage groove. A portion of the coil wound on the third bracket is located on one side of the second reinforcing block, and the other portion passes through the second wire passage groove to the other side of the second reinforcing block.

[0020] In one embodiment, the current sensor further includes a circuit board, the Hall element is disposed on the circuit board, and a second support portion is disposed on the second reinforcing block, the second support portion abutting against the circuit board.

[0021] In one embodiment, the first magnetic core has a first engagement portion and a second engagement portion at its two ends, the second magnetic core has a first mating portion at its end away from the third magnetic core, and the third magnetic core has a second mating portion at its end away from the second magnetic core. The first mating portion is inserted into the first engagement portion, and the second mating portion is inserted into the second engagement portion.

[0022] In one embodiment, the first magnetic core, the second magnetic core, and the third magnetic core each include a plurality of stacked laminations, and the lengths of two adjacent laminations are different.

[0023] The laminated sheets include silicon steel sheets or permalloy sheets.

[0024] In one embodiment, at least one of the first bracket and the second bracket is provided with a first pressing part, and the first mating part and the first biting part are inserted and mated at the first pressing part.

[0025] And / or, at least one of the first bracket and the fourth bracket is provided with a second clamping part, and the second mating part and the second biting part are clamped in the second clamping part.

[0026] In one embodiment, the bracket is provided with anti-detachment baffles at both ends, and the coil is limited between the two anti-detachment baffles of the corresponding bracket;

[0027] The anti-detachment baffle is provided with a clearance groove, which is used to avoid the anti-detachment baffle on the adjacent bracket.

[0028] In one embodiment, the current sensor further includes a circuit board, the Hall element is disposed on the circuit board, and at least one of the anti-detachment baffles is provided with a third support portion, the third support portion abutting against the circuit board.

[0029] In one embodiment, the current sensor further includes a circuit board and terminals. The Hall element is disposed on the circuit board, and the terminals are disposed on the anti-detachment baffle. The two ends of the coil are respectively connected to the terminals on the anti-detachment baffles at both ends of the corresponding bracket. The terminals are all in cooperation with the circuit board and electrically connect the corresponding coils to the circuit board. The circuit board enables the coils on any two adjacent brackets to be connected in series.

[0030] The aforementioned current sensor mounting bracket includes multiple supports arranged in a ring around each other. At least one support is longer than another, resulting in a bracket system with both long and short supports. This allows for the use of coils with different numbers of turns for supports of varying lengths. Since multiple coils are wound around multiple supports, the overall number of turns can be increased by using multiple supports to enhance the compensating magnetic field. Furthermore, because the number of turns is positively correlated with the length of the support, coils on supports of different lengths can maintain a consistent turn density, thereby improving magnetic field uniformity and ultimately enhancing the accuracy of the current sensor measurement. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of a current sensor according to an embodiment of this application.

[0032] Figure 2 This is a schematic diagram of the circuit board and Hall element in a current sensor according to an embodiment of this application.

[0033] Figure 3 This is a schematic diagram of the structure of a current sensor according to an embodiment of the present application, in which the coil is wound on the mounting bracket.

[0034] Figure 4 This is a schematic diagram of the structure of the magnetic ring in a current sensor according to an embodiment of this application.

[0035] Figure 5 for Figure 4 The diagram shows an exploded view of the magnetic ring of the current sensor.

[0036] Figure 6 for Figure 5 A magnified view of the structure within the middle circle.

[0037] Figure 7 This is a schematic diagram of the mounting bracket for a current sensor according to an embodiment of this application.

[0038] Figure 8 This is an exploded structural diagram of each magnetic core in the magnetic ring relative to each bracket in the mounting frame in a current sensor according to an embodiment of this application.

[0039] Figure 9 This is a schematic diagram of a current sensor according to an embodiment of the present application, in which each bracket of the mounting frame is in an assembled state and the coil is wound on the mounting frame.

[0040] Figure 10 This is a schematic diagram of the structure of a current sensor according to an embodiment of this application, showing the brackets of the mounting frame in an assembled state.

[0041] Figure 11 for Figure 10 A magnified view of the structure within the middle circle.

[0042] Figure 12 This is a three-dimensional structural diagram of a current sensor according to an embodiment of this application, with a housing installed.

[0043] Figure 13 for Figure 12 The diagram shows another view of the current sensor's structure.

[0044] Explanation of icon numbers:

[0045] 10. Mounting bracket; 11. Support; 111. First support; 112. Second support; 113. Third support; 114. Fourth support; 132. Second side; 12. Insertion hole; 13. First reinforcing block; 131. First wire guide groove; 132. First support part; 14. Second reinforcing block; 141. Second wire guide groove; 142. Second support part; 15. First clamping part; 16. Second clamping part; 17. Anti-detachment baffle; 171. Clearance groove; 172. Third support part; 20. Coil 30. Magnetic ring; 301. Air gap; 302. Laminated plate; 31. First magnetic core; 311. First engagement part; 312. Second engagement part; 32. Second magnetic core; 321. First sub-part; 322. First mating part; 33. Third magnetic core; 331. Second sub-part; 332. Second mating part; 40. Hall element; 50. Circuit board; 60. Terminal block; 70. Potentiometer; 80. Connector; 90. Housing; 91. Inner frame; 92. Outer frame; 93. Cover plate; 931. Perforation. Detailed Implementation

[0046] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0047] See Figures 1 to 4 As shown, a current sensor provided in one embodiment of this application includes a mounting bracket 10, a plurality of coils 20, a magnetic ring 30, and a Hall element 40.

[0048] The mounting frame 10 includes multiple supports 11 arranged in a ring around each other, meaning that the supports 11 are arranged end to end to form a ring. At least one support 11 is longer than another support 11. Therefore, the mounting frame 10 contains both longer and shorter supports 11, allowing for different numbers of coils 20 to be used for supports 11 of different lengths.

[0049] Multiple coils 20 are wound on multiple supports 11, and the number of turns of the coil 20 is positively correlated with the length of the support 11. That is, the longer the support 11 is, the more turns the coil 20 has; correspondingly, the shorter the support 11 is, the fewer turns the coil 20 has.

[0050] The magnetic ring 30 has an air gap 301 and is disposed within multiple supports 11 along the extension direction of the supports 11. At least one support 11 is provided with a socket 12. The position of the socket 12 corresponds to the position of the air gap 301. The Hall element 40 is inserted into the support 11 through the socket 12 and is located within the air gap 301. It should be noted that when the current sensor is working, the Hall element 40 monitors the magnetic field strength at the air gap 301 in real time and outputs a signal to drive the coil 20 to generate a reverse magnetic field. When the reverse magnetic field and the primary magnetic field completely cancel each other out at the air gap 301 (i.e., zero magnetic flux state), the magnetic field reaches equilibrium. Since the Hall element 40 is located within the air gap 301, the magnetic balance state is accurately fed back, ensuring that the compensation current is strictly proportional to the primary current, thereby achieving high-precision measurement.

[0051] In this application, since multiple coils 20 are wound around multiple supports 11, the overall number of turns of the coils 20 can be increased by using multiple supports 11 to increase the compensation magnetic field. Furthermore, since the number of turns of the coils 20 is positively correlated with the length of the support 11, the coils 20 on supports 11 of different lengths can maintain a consistent turn density, thereby improving magnetic field uniformity and thus enhancing the measurement accuracy of the current sensor.

[0052] In some embodiments, each coil 20 is uniformly wound on its corresponding support 11 with an equal number of turns. In this embodiment, the number of turns refers to the number of turns of the coil 20 per unit length. Because each coil 20 is uniformly wound on its corresponding support 11, the magnetic field at different locations on the same support 11 remains uniform. Furthermore, since the number of turns of each coil 20 is equal, the coils 20 on different supports 11 will also maintain a uniform magnetic field. Consequently, when multiple coils 20 are arranged along multiple supports 11 arranged in a ring, the overall magnetic field uniformity is good, which helps to improve measurement accuracy.

[0053] Combination Figure 4 and Figure 5 As shown, the magnetic ring 30 includes a first magnetic core 31, a second magnetic core 32, and a third magnetic core 33. The first magnetic core 31, the second magnetic core 32, and the third magnetic core 33 are arranged in a rectangular ring.

[0054] The first magnetic core 31 is in the shape of a straight bar, one end of the second magnetic core 32 and one end of the third magnetic core 33 are respectively connected to the two ends of the first magnetic core 31, and the other end of the second magnetic core 32 and the other end of the third magnetic core 33 form an air gap 301.

[0055] In this embodiment, the first magnetic core 31 serves as an important path for magnetic field conduction, forming a closed loop with the second magnetic core 32 and the third magnetic core 33 to concentrate and guide magnetic field lines to the air gap 301 region, thereby increasing the magnetic field strength at the air gap 301.

[0056] In addition, the first magnetic core 31, the second magnetic core 32 and the third magnetic core 33 are arranged in a rectangular ring, which makes the magnetic poles on both sides of the air gap 301 symmetrically distributed, thereby reducing the diffusion of magnetic flux at the edges, which helps to improve the uniformity of the magnetic field and thus improve the detection accuracy of the current sensor.

[0057] Furthermore, continue to combine Figure 4 and Figure 5 As shown, both the second magnetic core 32 and the third magnetic core 33 include two sub-sections that are perpendicularly connected to each other.

[0058] For ease of description, the sub-section of the second magnetic core 32 will be referred to as "first sub-section 321", and the sub-section of the third magnetic core 33 will be referred to as "second sub-section 331". Understandably, the two first sub-sections 321 of the second magnetic core 32 are connected perpendicularly to each other, and the two sub-sections of the third magnetic core 33 are connected perpendicularly to each other. Thus, both the second magnetic core 32 and the third magnetic core 33 are L-shaped, which facilitates their enclosure with the straight first magnetic core 31 to form a rectangular magnetic ring 30.

[0059] Combination Figure 4 and Figure 5 As shown, the first magnetic core 31 has a first engagement portion 311 and a second engagement portion 312 at its two ends, the second magnetic core 32 has a first mating portion 322 at its end away from the third magnetic core 33, and the third magnetic core 33 has a second mating portion 332 at its end away from the second magnetic core 32. The first mating portion 322 is inserted into the first engagement portion 311, and the second mating portion 332 is inserted into the second engagement portion 312.

[0060] In this embodiment, the insertion and engagement of the first engagement portion 311 and the first mating portion 322 form a mechanical interlock, and the insertion and engagement of the second engagement portion 312 and the second mating portion 332 also form a mechanical interlock. This improves the structural stability of the magnetic ring 30, which is composed of the first magnetic core 31, the second magnetic core 32, and the third magnetic core 33, thus ensuring the uniformity of the air gap 301. Furthermore, this insertion structure can also disperse vibration stress through the engagement surface, making it less likely for the magnetic core to dislodge due to vibration when the current sensor is used in vehicles or other applications.

[0061] It should be noted that the structural types of the first engagement part 311, the second engagement part 312, the first mating part 322 and the second mating part 332 can be slots and inserts.

[0062] For example, combining Figure 5 and Figure 6As shown, the first magnetic core 31, the second magnetic core 32, and the third magnetic core 33 each include multiple stacked laminations 302, and the lengths of adjacent laminations 302 are different. Because the lengths of adjacent laminations 302 are different, slots and inserts can be formed at the ends of the corresponding laminations 302. Thus, a first engaging portion 311 and a second engaging portion 312 are formed at both ends of the first magnetic core 31. Correspondingly, the second magnetic core 32 and the third magnetic core 33 respectively form the aforementioned first mating portion 322 and second mating portion 332. It should be noted that, for the air gap 301 between the second magnetic core 32 and the third magnetic core 33, in order to maintain the uniformity of the air gap 301, the opposite end faces of the second magnetic core 32 and the third magnetic core 33 are both flat. That is to say, the laminations 302 in the second magnetic core 32 are flush with the side corresponding to the third magnetic core 33, and the laminations 302 in the third magnetic core 33 are flush with the side corresponding to the second magnetic core 32.

[0063] It should be noted that since both the second magnetic core 32 and the third magnetic core 33 include two sub-parts that are perpendicularly connected to each other, the first magnetic core 31 and the third magnetic core 33 are both L-shaped. Therefore, the lamination 302 used to form the first magnetic core 31 and the third magnetic core 33 is an L-shaped lamination, and the first magnetic core 31 and the third magnetic core 33 formed by the stacking are both L-shaped.

[0064] It should be noted that the first magnetic core 31 can be formed by alternating stacks of two sets of straight strips 302 of different lengths. Both ends of the first magnetic core 31 have inserts and slots formed from the ends of the strips 302. The inserts and slots can be arranged alternately in the thickness direction of the strips 302, thus forming a first engaging portion 311 and a second engaging portion 312 at both ends of the first magnetic core 31. Correspondingly, the second magnetic core 32 and the third magnetic core 33 are each formed by stacking strips 302 of different lengths. The formation methods of the second magnetic core 32 and the third magnetic core 33 will not be elaborated here. For example, when the second magnetic core 32 and the third magnetic core 33 are formed by stacking laminations 302, the laminations 302 of the second magnetic core 32 have the same extension length in the direction near the air gap 301, and the laminations 302 of the third magnetic core 33 have the same extension length in the direction near the air gap 301, so that the end faces of the second magnetic core 32 and the third magnetic core 33 facing each other are flat, and air gaps 301 are formed at intervals.

[0065] Understandably, in the direction perpendicular to the first magnetic core 31, the laminations 302 of the second magnetic core 32 contain at least two sets of laminations 302 with different extension lengths. By alternately stacking laminations 302 with different extension lengths, the end of the second magnetic core 32 furthest from the air gap 301 can form a first mating portion 322 capable of engaging with the first engagement portion 311. Correspondingly, the end of the third magnetic core 33 furthest from the air gap 301 can also form a second mating portion 332 capable of engaging with the second engagement portion 312 through the stacking of laminations 302 with different lengths.

[0066] Based on the magnetic conductivity requirements of each magnetic core, the laminations 302 used in each magnetic core are all made of magnetically conductive secondary materials. For example, the laminations 302 include, but are not limited to, silicon steel sheets or permalloy sheets.

[0067] An insulating coating can be provided between the laminations 302. In this way, the insulating coating between the laminations 302 forms a resistive barrier, which confines the eddy current induced by the alternating magnetic field within a single lamination, thereby reducing eddy current loss.

[0068] Combination Figure 5 , Figure 7 and Figure 8 As shown, the mounting bracket 10 includes four supports 11: a first support 111, a second support 112, a third support 113, and a fourth support 114. A first magnetic core 31 passes through the first support 111. One first sub-part 321 of the second magnetic core 32 passes through the second support 112, another first sub-part 321 of the second magnetic core 32 passes through the third support 113, one second sub-part 331 of the third magnetic core 33 passes through the third support 113, and another second sub-part 331 of the third magnetic core 33 passes through the fourth support 114. The third support 113 is provided with an insertion hole 12. This structural arrangement facilitates the assembly of the first support 111, the second support 112, the third support 113, and the fourth support 114, ultimately allowing the magnetic ring 30 to be disposed within these four supports 11. Therefore, this structural arrangement improves the assembly efficiency of the magnetic ring 30 with the mounting bracket 10.

[0069] Combination Figure 8 and Figure 9As shown, in some embodiments, the length of the first support 111 is equal to the length of the third support 113, thereby facilitating the placement of coils 20 of the same specifications on both the first support 111 and the third support 113. That is, the number of turns of the coil 20 on the first support 111 is equal to the number of turns of the coil 20 on the third support 113. Correspondingly, the length of the second support 112 is equal to the length of the fourth support 114. This facilitates the placement of coils 20 of the same specifications on both the second support 112 and the fourth support 114; that is, the number of turns of the coil 20 on the second support 112 is equal to the number of turns of the coil 20 on the fourth support 114. In this way, when the first bracket 111, the second bracket 112, the third bracket 113 and the fourth bracket 114 are arranged in a rectangular enclosure, the ends of the coils 20 on each bracket 11 can be brought as close together as possible, so as to reduce the area of ​​the mounting frame 10 where the coils 20 are not wound in the circumferential direction. In other words, this structural arrangement is conducive to improving the number of turns and uniformity of the coils 20, thereby increasing the compensation magnetic field and improving the detection accuracy of the current sensor.

[0070] In some embodiments, the length of the first bracket 111 is greater than the length of the second bracket 112. That is, among the four brackets 11, the first bracket 111 and the third bracket 113 are two brackets 11 of equal and longer length, while the second bracket 112 and the fourth bracket 114 are two brackets 11 of equal and shorter length. With this arrangement, the mounting frame 10 is generally rectangular. Since the number of turns of the coil 20 is positively correlated with the length of the bracket 11 it is on, the number of turns of the coil 20 on the first bracket 111 and the third bracket 113 is equal and greater than the number of turns of the coil 20 on the second bracket 112 and the fourth bracket 114. Understandably, the number of turns of the coil 20 on the second bracket 112 and the fourth bracket 114 is equal. This structural arrangement maintains a sufficient number of coil 20 turns and maintains magnetic field uniformity, while reducing the size of the portion of the mounting frame 10 corresponding to the second bracket 112, thereby facilitating the installation and application of the current sensor in narrow installation environments.

[0071] Combination Figures 1 to 3 As shown, the current sensor also includes a circuit board 50, on which a Hall element 40 is disposed. The Hall element 40 has a pin portion, which is electrically connected to the circuit board 50. It should be noted that structures such as a potentiometer 70 and a connector 80 may also be disposed on the circuit board 50.

[0072] In some embodiments, the first bracket 111 is provided with a first reinforcing block 13, and the first reinforcing block 13 is provided with a first wire passage groove 131. A portion of the coil 20 wound on the first bracket 111 is located on one side of the first reinforcing block 13, and the other portion passes through the first wire passage groove 131 to the other side of the first reinforcing block 13.

[0073] In this embodiment, the first reinforcing block 13 acts as a physical isolation barrier, dividing the coil 20 on the first bracket 111 into two independent regions on both sides, effectively suppressing the displacement of the coil 20 due to vibration caused by its excessive length. Furthermore, when the coil 20 on the first bracket 111 passes through the first wire groove 131, the groove wall of the first wire groove 131 has a positioning constraint effect on the cable, thereby further improving the stability of the coil 20 on the first bracket 111.

[0074] The first reinforcing block 13 may be integrally formed on the first bracket 111, or it may be connected to the first bracket 111 by means of snap-fit ​​or glue connection. In some embodiments, the first reinforcing block 13 is ring-shaped and sleeved on the first bracket 111.

[0075] The first reinforcing block 13 can be located at the middle of the first support 111, which corresponds to the midpoint of the line connecting the two ends of the first support 111. This ensures that the coil 20 on the first support 111 has the same number of turns on different sides corresponding to the first reinforcing block 13, which helps to improve the uniformity of the magnetic field.

[0076] The socket 12 is disposed on the first reinforcing block 13, and the first reinforcing block 13 is provided with a first support portion 132, which abuts against the circuit board 50. In this embodiment, by disposing of the socket 12 on the first reinforcing block 13, the extension dimension of the hole wall of the socket 12 can be increased by utilizing the first reinforcing block 13. This facilitates the Hall element 40 entering the air gap 301 from the socket 12. Within the air gap 301, the Hall element 40 is in a relatively enclosed space and is protected from external magnetic field interference, thereby improving the detection accuracy of the current sensor.

[0077] In some embodiments, the third support 113 is provided with a second reinforcing block 14, and the second reinforcing block 14 is provided with a second wire passage groove 141. A portion of the coil 20 wound on the third support 113 is located on one side of the second reinforcing block 14, and the other portion passes through the second wire passage groove 141 to the other side of the second reinforcing block 14. In this embodiment, the second reinforcing block 14 acts as a physical isolation barrier, dividing the coil 20 on the third support 113 into two independent regions, effectively suppressing the displacement caused by vibration due to the excessive length of the coil 20. Furthermore, when the coil 20 on the third support 113 passes through the second wire passage groove 141, the groove wall of the second wire passage groove 141 has a positioning constraint effect on the cable, thereby further improving the stability of the coil 20 on the second support 112.

[0078] The second reinforcing block 14 may be integrally formed on the third bracket 113, or it may be connected to the third bracket 113 by means of snap-fit ​​or glue connection. In some embodiments, the second reinforcing block 14 is ring-shaped and sleeved on the third bracket 113.

[0079] The second reinforcing block 14 can be located at the middle of the third support 113, corresponding to the midpoint of the line connecting the two ends of the third support 113. This ensures that the coil 20 on the third support 113 has the same number of turns on different sides corresponding to the second reinforcing block 14, which helps to improve the uniformity of the magnetic field.

[0080] Furthermore, a second support portion 142 is provided on the second reinforcing block 14. The second support portion 142 abuts against the circuit board 50, so that during the installation process of the mounting bracket 10 and the circuit board 50, the second support portion 142 can achieve positioning by abutting against the circuit board 50, which helps to improve the installation stability between the mounting bracket 10 and the circuit board 50.

[0081] Combination Figure 1 , Figure 5 and Figure 9 As shown, in some embodiments, at least one of the first bracket 111 and the second bracket 112 is provided with a first pressing part 15. The first mating part 322 and the first engaging part 311 are inserted into each other (i.e., the position where the first magnetic core 31 and the second magnetic core 32 are inserted into each other) and clamped in the first pressing part 15. In this way, the first pressing part 15 is used to press the position where the first magnetic core 31 and the second magnetic core 32 are inserted into each other to improve assembly stability and reduce the probability of loosening.

[0082] At least one of the first bracket 111 and the fourth bracket 114 is provided with a second pressing part 16. The second mating part 332 and the second engaging part 312 are inserted into each other (i.e., the position where the first magnetic core 31 and the third magnetic core 33 are inserted into each other) and are clamped in the second pressing part 16. The second pressing part 16 is used to press the position where the first magnetic core 31 and the third magnetic core 33 are inserted into each other to improve assembly stability and reduce the probability of loosening.

[0083] It should be noted that the first pressing part 15 can be integrally formed on the first bracket 111 or the second bracket 112, or it can be connected to the first bracket 111 or the second bracket 112 by means of snap-fit ​​or glue connection.

[0084] Accordingly, the second clamping part 16 may be integrally formed on the first bracket 111 or the fourth bracket 114, or it may be connected to the first bracket 111 or the fourth bracket 114 by means of snap-fit ​​or glue connection.

[0085] The structures of the first clamping part 15 and the second clamping part 16 may be the same or different. In some embodiments, both the first clamping part 15 and the second clamping part 16 include two spaced-apart pressure plates. Thus, the two pressure plates of the first clamping part 15 can clamp the first magnetic core 31 and the second magnetic core 32 at their interlocking positions, and the two pressure plates of the second clamping part 16 can clamp the first magnetic core 31 and the third magnetic core 33 at their interlocking positions.

[0086] In some embodiments, the structure of the third bracket 113 is the same as that of the first bracket 111, and the structure of the second bracket 112 is the same as that of the fourth bracket 114. This reduces the number of bracket types, thereby simplifying the assembly of the mounting bracket 10 and reducing the probability of incorrect installation during assembly.

[0087] Combination Figure 9 As shown, the bracket 11 is provided with anti-detachment baffles 17 at both ends, and the coil 20 is limited between the two anti-detachment baffles 17 of the corresponding bracket 11, thereby preventing the coil 20 from coming off from both ends of the bracket 11 and improving the installation stability of the coil 20 relative to the bracket 11.

[0088] The anti-detachment baffle 17 can be integrally formed on the bracket 11, or it can be connected to the bracket 11 by means of snap-fit ​​or glue connection.

[0089] like Figure 9 As shown, in the embodiment where the mounting frame 10 includes four supports 11 (i.e., the first support 111, the second support 112, the third support 113 and the fourth support 114), both ends of the first support 111, the second support 112, the third support 113 and the fourth support 114 are provided with anti-detachment baffles 17.

[0090] Combination Figure 10 and Figure 11 As shown, the anti-detachment baffle 17 is provided with a clearance groove 171, which is used to avoid interference between the anti-detachment baffles 17 on adjacent brackets 11. It should be noted that the clearance groove 171 makes it less likely for the anti-detachment baffles 17 on adjacent brackets 11 to interfere, thus allowing for a more compact installation between the brackets 11. This facilitates bringing the ends of the coils 20 on adjacent brackets 11 as close as possible, thereby reducing the area on the mounting frame 10 where the coils 20 are not wound. Therefore, this structural design improves the compactness of the installation between multiple brackets 11 in the mounting frame 10 and helps to increase the number of turns of the coil 20, thereby increasing the compensating magnetic field.

[0091] Recombined Figures 1 to 3 As shown, in the embodiment where the Hall element 40 is disposed on the circuit board 50, at least one anti-detachment baffle 17 is provided with a third support portion 172. The third support portion 172 abuts against the circuit board 50, so that during the installation process of the mounting bracket 10 and the circuit board 50, the third support portion 172 can be positioned by abutting against the circuit board 50, which helps to improve the installation stability between the mounting bracket 10 and the circuit board 50.

[0092] Furthermore, the current sensor also includes terminals 60, which are disposed on the anti-detachment baffles 17. The two ends of the coil 20 are respectively connected to the terminals 60 on the anti-detachment baffles 17 at both ends of the corresponding bracket 11. The terminals 60 all mate with the circuit board 50, electrically connecting the corresponding coil 20 to the circuit board 50. In this embodiment, because the terminals 60 are disposed on the anti-detachment baffles 17, when the bracket 11 and the circuit board 50 are assembled together, the terminals 60 on the anti-detachment baffles 17 mate with the circuit board 50, and the coil 20 is electrically connected to the circuit board 50 through the terminals 60. Therefore, this structural arrangement allows for the establishment of an electrical path while fixing the ends of the coil 20, thereby improving assembly efficiency.

[0093] It should be noted that the circuit board 50 is equipped with wiring. In this embodiment, the circuit board 50 connects the coils 20 on any two adjacent supports 11 in series, thereby superimposing the magnetic flux of the coils 20 on multiple supports 11 in the same direction to enhance the magnetic field strength.

[0094] The terminal block 60 can be a metallized hole inserted into the circuit board 50 (electrically connected to the circuitry of the circuit board 50), thereby enabling the terminal block 60 to be electrically connected to the circuit board 50 through the metallized hole. It should be noted that after the terminal block 60 is inserted into the metallized hole, it can be fixed with solder. In this way, soldering not only improves the connection stability between the terminal block 60 and the circuit board 50, but also reduces the probability of poor electrical connection between the terminal block 60 and the circuit board 50.

[0095] In this application, coil 20 includes, but is not limited to, enameled wire.

[0096] Combination Figure 12 and Figure 13 As shown, the current sensor also includes a housing 90, which has a receiving cavity, and structures such as the mounting bracket 10, coil 20, and circuit board 50 are located inside the receiving cavity.

[0097] When the circuit board 50 is installed in the accommodating cavity, the end of the connector 80 away from the circuit board 50 extends out of the housing 90, thereby facilitating the electrical connection of the current sensor to an external device using the connector 80.

[0098] The housing 90 includes an inner frame 91 and an outer frame 92, with a accommodating cavity formed between the inner frame 91 and the outer frame 92. The circuit board 50 has a cutout groove, making the circuit board 50 annular in shape. Thus, after engaging with the annular mounting bracket 10, the circuit board 50 can be assembled between the inner frame 91 and the outer frame 92. Understandably, both ends of the inner frame 91 have openings, allowing the space enclosed by the inner frame 91 to be used for the insertion of a test object. That is, when the test object is inserted into the inner frame 91, it is located within the space enclosed by the magnetic ring 30, allowing the change in magnetic field caused by the change in the current of the test object to be detected by the Hall element 40 located in the air gap 301.

[0099] The inner frame 91 and the outer frame 92 can be a one-piece molded structure to improve the overall structural stability of the shell 90.

[0100] The housing 90 also includes a cover plate 93 disposed between the inner frame 91 and the outer frame 92. The cover plate 93 covers the opening of the accommodating cavity, thereby providing a dustproof effect and reducing the amount of dust entering the accommodating cavity. A through hole 931 is provided on the cover plate 93 corresponding to the position of the connector 80, allowing the connector 80 to protrude from the housing 90 through the through hole 931, thus meeting the needs of electrical connection with external devices. In other embodiments, the cover plate 93 may be omitted, and the inner frame 91 and the outer frame 92 may be sealed with potting compound. The potting compound encapsulates the mounting bracket 10, multiple coils 20, magnetic ring 30, and Hall element 40, forming a sealed and insulating protection.

[0101] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0102] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0103] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0104] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0105] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0106] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0107] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A current sensor, characterized in that, include: The mounting frame includes multiple supports arranged in a ring around each other, and the length of at least one of the supports is greater than the length of another support. Multiple coils are wound one-to-one on multiple brackets, and the number of turns of each coil is positively correlated with the length of the bracket it is located on; A magnetic ring having an air gap is disposed within a plurality of brackets along the extending direction of the brackets. At least one bracket is provided with an insertion hole, the position of which corresponds to the position of the air gap. A Hall element is inserted into the bracket through the socket and located within the air gap.

2. The current sensor according to claim 1, characterized in that, Each of the coils is uniformly wound on the corresponding bracket, and the number of turns is equal.

3. The current sensor according to claim 1, characterized in that, The magnetic ring includes a first magnetic core, a second magnetic core, and a third magnetic core, wherein the first magnetic core, the second magnetic core, and the third magnetic core are arranged in a rectangular ring. The first magnetic core is in the shape of a straight bar. One end of the second magnetic core and one end of the third magnetic core are respectively connected to the two ends of the first magnetic core. The other ends of the second magnetic core and the other ends of the third magnetic core are spaced apart to form the air gap.

4. The current sensor according to claim 3, characterized in that, Both the second magnetic core and the third magnetic core include two sub-sections that are perpendicularly connected to each other; the mounting bracket includes four brackets, namely the first bracket, the second bracket, the third bracket and the fourth bracket; The first magnetic core is inserted through the first bracket, one of the sub-parts of the second magnetic core is inserted through the second bracket, the other sub-part of the second magnetic core is inserted through the third bracket, one of the sub-parts of the third magnetic core is inserted through the third bracket, and the other sub-part of the third magnetic core is inserted through the fourth bracket, wherein the third bracket is provided with the insertion hole.

5. The current sensor according to claim 4, characterized in that, The length of the first bracket is equal to the length of the third bracket; the length of the second bracket is equal to the length of the fourth bracket.

6. The current sensor according to claim 5, characterized in that, The length of the first bracket is greater than the length of the second bracket.

7. The current sensor according to claim 6, characterized in that, The first bracket is provided with a first reinforcing block, and the first reinforcing block is provided with a first wire passage groove. A portion of the coil wound on the first bracket is located on one side of the first reinforcing block, and the other portion passes through the first wire passage groove to the other side of the first reinforcing block.

8. The current sensor according to claim 7, characterized in that, The socket is disposed on the first reinforcing block, the current sensor further includes a circuit board, the Hall element is disposed on the circuit board, the first reinforcing block is provided with a first support portion, and the first support portion abuts against the circuit board.

9. The current sensor according to claim 7, characterized in that, The third bracket is provided with a second reinforcing block, and the second reinforcing block is provided with a second wire passage groove. A portion of the coil wound on the third bracket is located on one side of the second reinforcing block, and the other portion passes through the second wire passage groove to the other side of the second reinforcing block.

10. The current sensor according to claim 9, characterized in that, The current sensor also includes a circuit board, the Hall element is disposed on the circuit board, and the second reinforcing block is provided with a second support portion, which abuts against the circuit board.

11. The current sensor according to claim 4, characterized in that, The first magnetic core has a first engagement portion and a second engagement portion at its two ends respectively. The second magnetic core has a first mating portion at the end away from the third magnetic core, and the third magnetic core has a second mating portion at the end away from the second magnetic core. The first mating portion is inserted into the first engagement portion, and the second mating portion is inserted into the second engagement portion.

12. The current sensor according to claim 11, characterized in that, The first magnetic core, the second magnetic core, and the third magnetic core each include multiple stacked laminations, and the lengths of two adjacent laminations are different. The laminated sheets include silicon steel sheets or permalloy sheets.

13. The current sensor according to claim 12, characterized in that, At least one of the first bracket and the second bracket is provided with a first pressing part, and the first mating part and the first biting part are inserted and mated at the first pressing part; And / or, at least one of the first bracket and the fourth bracket is provided with a second clamping part, and the second mating part and the second biting part are clamped in the second clamping part.

14. The current sensor according to claim 12, characterized in that, The bracket is provided with anti-detachment baffles at both ends, and the coil is limited between the two anti-detachment baffles of the corresponding bracket; The anti-detachment baffle is provided with a clearance groove, which is used to avoid the anti-detachment baffle on the adjacent bracket.

15. The current sensor according to claim 14, characterized in that, The current sensor also includes a circuit board, the Hall element is disposed on the circuit board, and at least one of the anti-detachment baffles is provided with a third support portion, the third support portion abutting against the circuit board.

16. The current sensor according to claim 14, characterized in that, The current sensor also includes a circuit board and terminals. The Hall element is disposed on the circuit board, and the terminals are disposed on the anti-disengagement baffle. The two ends of the coil are respectively connected to the terminals on the anti-disengagement baffles at both ends of the corresponding bracket. The terminals are all in cooperation with the circuit board and electrically connect the corresponding coils to the circuit board. The circuit board enables the coils on any two adjacent brackets to be connected in series.

Images