Current sensing device

Abstract

A current sensing device may include an integrated trace-type current sensor assembly. The current sensor assembly may include a chip body, an integrated electrical conductor, and a current sensor. The current sensor measures the amount of a first current flowing through the integrated electrical conductor. The current sensing device may also include an external resistive element connected in parallel with the integrated electrical conductor. A second current may flow through the external resistive element. The amount of the first current measured by the current sensor indicates the total current as the sum of the first and second currents. The total current may be determined based on the amount of the first current measured by the current sensor, a first resistance value based on the integrated electrical conductor, and a second resistance value based on the external resistive element.

Description

[0001] Related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 656,748, filed June 6, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] Some disclosed implementations involve using current sensor assemblies to determine the current value of components of electronic / electrical devices, such as power tools, power tool battery packs, portable power supplies, bidirectional power converters included in electronic devices, etc. Background Technology

[0004] Electronic / electrical devices such as those described above may include one or more current sensor assemblies to monitor the current of one or more components of the electronic device. This monitoring of current allows the control system of each electronic device to determine how to control the device. For example, one or more components of the electronic device may be controlled based on the monitored current of one or more other components (e.g., current monitoring during charging or discharging of a battery pack, current monitoring during power conversion in a power converter, overcurrent shutdown, motor control based on current monitoring, etc.).

[0005] Current sensor assemblies included in electronic devices can include one of two types: (i) integrated trace (i.e., internal trace) type current sensor assemblies and (ii) external trace type current sensor assemblies. For integrated trace type current sensor assemblies, the current to be measured flows through an electrical conductor integrated into the sensor assembly itself. On the other hand, for external trace type current sensor assemblies, the sensor assembly is designed to be placed adjacent to an external electrical conductor through which the current to be measured flows.

[0006] Each of the two types of current sensor assemblies described above has its advantages and disadvantages, which lead to trade-offs when choosing which type of current sensor assembly to use for a given application. Specifically, external trace current sensor assemblies are more difficult to use / install than integrated trace current sensor assemblies because they may require additional board design, additional sensor mounting, and additional post-assembly calibration compared to integrated trace current sensor assemblies. However, as a trade-off for the additional design and calibration, external trace current sensor assemblies can be designed to measure larger currents than integrated trace current sensor assemblies. In other words, external trace current sensor assemblies generally have a larger current measurement range (e.g., they can measure higher currents) than integrated trace current sensor assemblies. Utility Model Content

[0007] Some disclosed embodiments involve extending the measurement range of an integrated trace current sensor assembly to allow it to indicate a wider range of measured current values ​​than it could otherwise measure. The additional components (e.g., one or more additional external resistors) included in the disclosed embodiments allow the integrated trace current sensor assembly to indicate higher current measurements compared to using only the integrated trace current sensor assembly without the additional components disclosed herein. Therefore, the systems, methods, and apparatuses disclosed herein achieve a greater current measurement range typically provided only by external trace current sensor assemblies while maintaining the ease of use / installation of the integrated trace current sensor assembly.

[0008] One embodiment provides a current sensing device that may include an integrated trace-type current sensor assembly. The integrated trace-type current sensor assembly may include a chip body and an integrated electrical conductor located in or on the chip body. A first current may flow through the integrated electrical conductor. The integrated trace-type current sensor assembly may further include a current sensor located in or on the chip body. The current sensor may be configured to measure the amount of the first current. The current sensing device may further include an external resistive element connected in parallel with the integrated electrical conductor. A second current may flow through the external resistive element. The total current, the sum of the first and second currents, may be determined based on the amount of the first current measured by the current sensor, a first resistance value of the integrated electrical conductor, and a second resistance value of the external resistive element. A first range of current values ​​that can be determined based on the current measurement from this current sensing device is greater than a second range of current values ​​that can only be measured by the integrated trace-type current sensor assembly when the integrated electrical conductor is not connected in parallel with the external resistive element.

[0009] In addition to any combination of the features described above, the current sensing device may include an electronic processor configured to determine the total current based on the amount of a first current measured by a current sensor, a first resistance value of an integrated electrical conductor, and a second resistance value of an external resistive element.

[0010] In addition to any combination of the features described above, the electronic processor can be integrated within the chip body.

[0011] In addition to any combination of the features described above, the electronic processor can be decoupled from the integrated trace-type current sensor assembly. The electronic processor can receive a measurement signal from the integrated trace-type current sensor assembly, which indicates the amount of a first current measured by the current sensor.

[0012] Another embodiment provides a current sensing device that may include an integrated trace-type current sensor assembly. The integrated trace-type current sensor assembly may include a chip body and an integrated electrical conductor located in or on the chip body. A first current may flow through the integrated electrical conductor. The integrated trace-type current sensor assembly may further include a current sensor located in or on the chip body. The current sensor may be configured to measure the amount of the first current. The current sensing device may further include an external resistive element connected in parallel with the integrated electrical conductor. A second current may flow through the external resistive element. The amount of the first current measured by the current sensor may indicate the total current as the sum of the first and second currents.

[0013] In addition to any combination of the features described above, a first range of the total current value that can be indicated by the current sensing device may be greater than a second range of the total current value that can be indicated by the integrated trace-type current sensor assembly (i) when the integrated conductor is not connected in parallel to the external resistive element (ii) such that the entire total current passes through the integrated conductor.

[0014] In addition to any combination of the features described above, the integrated trace-type current sensor assembly and the external resistive element can be mounted on a printed circuit board (PCB). A first conductive trace on the PCB can be connected to a first pin of the chip body. The first pin can be connected to a first end of the integrated electrical conductor. The first conductive trace can be connected to a first end of the external resistive element. A second conductive trace on the PCB can be connected to a second pin of the chip body. The second pin can be connected to a second end of the integrated electrical conductor, opposite to the first end of the integrated electrical conductor. The second conductive trace can be connected to a second end of the external resistive element, opposite to the first end of the external resistive element.

[0015] In addition to any combination of the features described above, the current sensing device may include an electronic processor configured to determine the total current based on the amount of a first current measured by a current sensor, a first resistance value of an integrated electrical conductor, and a second resistance value of an external resistive element.

[0016] In addition to any combination of the features described above, the electronic processor can be integrated within the chip body.

[0017] In addition to any combination of the features described above, the electronic processor can be decoupled from the integrated trace-type current sensor assembly. The electronic processor can receive a measurement signal from the integrated trace-type current sensor assembly, which indicates the amount of a first current measured by the current sensor.

[0018] In addition to any combination of the features described above, the current sensing device may include a second external resistive element connected in series with the integrated electrical conductor, such that the external resistive element is connected in parallel with the series combination of the second external resistive element and the integrated electrical conductor. A first current may flow through the second external resistive element.

[0019] In addition to any combination of the features described above, the second external resistive element may include a first tolerance and a first temperature coefficient of resistance of the initial resistance, wherein the first tolerance of the initial resistance is less than the second tolerance of the initial resistance of the integrated electrical conductor, and the first temperature coefficient of resistance is less than the second temperature coefficient of resistance of the integrated electrical conductor.

[0020] In addition to any combination of the features described above, the first accuracy of a current sensing device can be less sensitive to changes in the first resistance value of the integrated electrical conductor than the second accuracy of a current sensing device without a second external resistive element.

[0021] In addition to any combination of the features described above, the integrated trace-type current sensor assembly, the external resistive element, and the second external resistive element can be mounted on a printed circuit board (PCB). A first conductive trace on the PCB can be connected to a first terminal of the external resistive element and a first terminal of the second external resistive element. A second conductive trace on the PCB can be connected between (i) a second terminal of the second external resistive element opposite to its first terminal and (ii) a first pin of the chip body. The first pin can be connected to a first terminal of the integrated conductor. A third conductive trace on the PCB can be connected to a second pin of the chip body. The second pin can be connected to a second terminal of the integrated conductor opposite to its first terminal. The third conductive trace can be connected to a second terminal of the external resistive element opposite to its first terminal.

[0022] In addition to any combination of the features described above, the current sensing device may be implemented in at least one of the following groups: power tool battery pack, power tool, portable power supply, first bidirectional power converter included in power tool battery pack, second bidirectional power converter included in power tool, third bidirectional power converter included in portable power supply, and combinations thereof.

[0023] Another embodiment provides a current sensing device that may include an integrated trace-type current sensor assembly. The integrated trace-type current sensor assembly may include a chip body and an integrated electrical conductor located in or on the chip body. A first current may flow through the integrated electrical conductor. The integrated trace-type current sensor assembly may further include a current sensor located in or on the chip body. The current sensor may be configured to measure the amount of the first current. The current sensing device may further include a first external resistive element connected in parallel with the integrated electrical conductor. A second current may flow through the first external resistive element. The current sensing device may include a second external resistive element connected in series with the integrated electrical conductor such that the first external resistive element is connected in parallel with the series combination of the second external resistive element and the integrated electrical conductor. The first current may flow through the second external resistive element. The total current, the sum of the first and second currents, may be determined based on the amount of the first current measured by the current sensor, a first resistance value based on the integrated electrical conductor, a second resistance value based on the first external resistive element, and a third resistance value based on the second external resistive element.

[0024] In addition to any combination of the features described above, the second external resistive element may include a first tolerance and a first temperature coefficient of resistance of the initial resistance, wherein the first tolerance of the initial resistance is less than the second tolerance of the initial resistance of the integrated electrical conductor, and the first temperature coefficient of resistance is less than the second temperature coefficient of resistance of the integrated electrical conductor.

[0025] In addition to any combination of the features described above, the first accuracy of a current sensing device can be less sensitive to changes in the first resistance value of the integrated electrical conductor than the second accuracy of a current sensing device without a second external resistive element.

[0026] In addition to any combination of the features described above, the integrated trace-type current sensor assembly, the first external resistor element, and the second external resistor element can be mounted on a printed circuit board (PCB). A first conductive trace on the PCB can be connected to a first terminal of the first external resistor element and a first terminal of the second external resistor element. A second conductive trace on the PCB can be connected between (i) a second terminal of the second external resistor element opposite to its first terminal and (ii) a first pin of the chip body. The first pin can be connected to a first terminal of the integrated conductor. A third conductive trace on the PCB can be connected to a second pin of the chip body. The second pin can be connected to a second terminal of the integrated conductor opposite to its first terminal. The third conductive trace can be connected to a second terminal of the first external resistor element opposite to its first terminal.

[0027] In addition to any combination of the features described above, the current sensing device may be implemented in at least one of the following groups: power tool battery pack, power tool, portable power supply, first bidirectional power converter included in power tool battery pack, second bidirectional power converter included in power tool, third bidirectional power converter included in portable power supply, and combinations thereof.

[0028] Before explaining any implementation in detail, it should be understood that the application of the implementation is not limited to the details of the configuration and arrangement of the components described in the following description or shown in the drawings. The implementation can be practiced or implemented in various ways. Furthermore, it should be understood that the wording and terminology used in this invention are for illustrative purposes and should not be considered restrictive. The use of “comprising,” “including,” or “having,” and variations thereof is intended to cover the items listed thereafter and their equivalents, as well as additional items. Unless otherwise stated or limited, the terms “mounted,” “connected,” “supported,” and “coupled,” and variations thereof are used broadly and cover direct and indirect mounting, connection, support, and coupling.

[0029] Unless the context clearly indicates otherwise, the articles “a,” “an,” and “the” should not be interpreted as meaning “one” or “only one.” Instead, these articles should be interpreted as meaning “at least one” or “one or more.” Similarly, when the terms “the” or “said” are used to refer to a noun previously introduced by the indefinite articles “a” or “an,” “the” and “said” mean “at least one” or “one or more,” unless the usage clearly indicates otherwise.

[0030] Furthermore, it should be understood that implementations may include hardware, software, and electronic components or modules, and for the purposes of discussion, the illustrations and descriptions of these components or modules may be presented as if most components were implemented solely in hardware. However, those skilled in the art will recognize from this detailed description that, in at least one implementation, the electronic aspects may be implemented as software (e.g., stored on a non-transitory computer-readable medium) executable by one or more processing units (such as microprocessors and / or application-specific integrated circuits (“ASICs”)). Therefore, it should be noted that these implementations may be implemented using a plurality of hardware and software-based devices and a plurality of different structural components. For example, “server,” “computing device,” “controller,” “processor,” etc., described in the specification may include one or more processing units, one or more computer-readable medium modules, one or more input / output interfaces, and various connectors (e.g., system buses) for connecting components.

[0031] Related terms used in conjunction with quantities or conditions, such as, for example, “about,” “approximately,” “generally,” etc., will be understood by one of ordinary skill in the art to include the stated value and have a meaning defined by the context (e.g., the term includes at least the degree of error associated with the accuracy of the measurement, the tolerance associated with a particular value [e.g., manufacturing, assembly, use, etc.]). Such terms should also be considered to disclose a range defined by the absolute values ​​of two endpoints. For example, the statement “about 2 to about 4” also discloses a range of “2 to 4.” Related terms may refer to a percentage added to or subtracted from the indicated value (e.g., 1%, 5%, 10% or more).

[0032] It should be understood that although some figures show hardware and software located within a particular device, these depictions are for illustrative purposes only. Functions described in this invention as being performed by a single component can be performed by multiple components in a distributed manner. Similarly, functions performed by multiple components can be combined and performed by a single component. In some embodiments, the components shown can be combined or divided into separate software, firmware, and / or hardware. For example, logic and processing can be distributed among multiple electronic processors, rather than residing within and being performed by a single electronic processor. Regardless of how the hardware and software components are combined or divided, the hardware and software components can reside on the same computing device or can be distributed among different computing devices connected via one or more networks or other suitable communication links. Similarly, components described as performing specific functions can also perform additional functions not described in this invention. For example, a device or structure "configured" in a certain way is at least configured in that way, but can also be configured in a way not explicitly listed.

[0033] Therefore, in the claims, if the device, method, or system is claimed to include, for example, a controller, control unit, electronic processor, computing device, logic element, module, memory module, communication channel or network, or other elements configured in a certain way to perform, for example, multiple functions, then the claims or claim elements should be interpreted as referring to one or more such elements, any one of which is configured to, for example, implement any one or more of the multiple functions, such that one or more elements together perform multiple functions.

[0034] Other aspects of the described embodiments will become apparent upon careful reading of the detailed description and accompanying drawings. Attached Figure Description

[0035] Figure 1 This is a simplified block diagram of an electronic / electrical device including a bidirectional power converter according to some exemplary embodiments.

[0036] Figures 2A-2CAccording to some exemplary embodiments, including Figure 1 A three-dimensional diagram of the different electronic components of a bidirectional power converter.

[0037] Figure 3 This is based on some exemplary implementation methods. Figure 1 A simplified block diagram of the inverter bridge of a bidirectional power converter.

[0038] Figure 4A A schematic diagram of a current sensing device according to a first exemplary embodiment is shown.

[0039] Figure 4B The following are illustrated according to some exemplary embodiments. Figure 4A Circuit diagram / circuit board layout of the current sensing device.

[0040] Figure 5A A schematic diagram of a current sensing device according to a second exemplary embodiment is shown.

[0041] Figure 5B The following are illustrated according to some exemplary embodiments. Figure 5A Circuit diagram / circuit board layout of the current sensing device. Detailed Implementation

[0042] Figure 1 A simplified block diagram of an example electronic (i.e., electrical) device 100 is shown. The electronic device 100 includes a battery system 110, an alternating current (AC) power source or load 120, and a bidirectional power converter 130 electrically connected between the battery system 110 and the AC power source or load 120. The bidirectional power converter 130 is configured to convert direct current (DC) to alternating current (AC), and also configured to convert AC to DC. For example, the bidirectional power converter 130 converts DC power from the battery system 110 to AC power for the load 120, and converts AC power from the AC power source 120 to DC power to charge the battery system 110. In some cases, the bidirectional power converter 130 can be used in the electronic device 100 (e.g., the power tool 100C as explained in this invention), such that even though the bidirectional power converter 130 may be able to convert current in opposite directions, the current is still converted in only one direction (e.g., from the battery system 110 to the load 120).

[0043] Figure 2AAn example electronic device 100 in the form of a portable power supply / power source 100A is shown. The portable power supply 100A includes a housing 205 for accommodating an internal battery system 210. The housing 205 also includes an input / output panel 215. The input / output panel 215 includes a power input section 220 and a power output section 225. The power output section 225 is, for example, an AC outlet for powering an AC electronic device. The internal battery system 210 corresponds to a battery system 110. In some cases, the internal battery system includes an integrated battery cell that is not configured to be removable by the user from the housing 205. The power input section 220 and the power output section 225 correspond to an AC power source 120 or an AC load 120, respectively. A bidirectional power converter 130 is coupled between the internal battery system 210, the power input section 220, and the power output section 225. The bidirectional power converter 130 converts DC power from the internal battery system 210 into AC power for the power output section 225. The bidirectional power converter 130 also converts AC power from the power input section 220 into DC power for charging the internal battery system 210. The portable power supply 100A may include additional components besides those described and shown in this invention. For example, the portable power supply 100A may include an additional power output section 225 (e.g., both AC and DC), a display, etc.

[0044] Figure 2BAn example electronic device 100 in the form of another portable power supply / power generation device 100B is shown. The portable power supply 100B includes a housing 230 having a first battery interface 235A and a second battery interface 235B. The first battery interface 235A and the second battery interface 235B are configured to receive a first removable power tool battery pack 240A and a second removable power tool battery pack 240B, respectively. The first removable power tool battery pack 240A and the second removable power tool battery pack 240B, individually referred to as removable power tool battery pack 240, are, for example, lithium-ion power tool battery packs having nominal voltages of 12 volts, 18 volts, 24 volts, 36 volts, 54 volts, 72 volts, 90 volts, 108 volts, etc. The removable power tool battery pack 240 can be used to power cordless indoor and outdoor power tools. The portable power supply 100B also includes a power input section 245 and a power output section 250. The power output section 250 is, for example, an AC outlet for powering AC electronic devices. The removable power tool battery pack 240 corresponds to the battery system 110. The power input section 245 and the power output section 250 correspond to the AC power source 120 or the AC load 120, respectively. A bidirectional power converter 130 is coupled between the removable power tool battery pack 240, the power input section 245, and the power output section 250. The bidirectional power converter 130 converts DC power from the removable power tool battery pack 240 into AC power for the power output section 250. The bidirectional power converter 130 also converts AC power from the power input section 245 into DC power for charging the removable power tool battery pack 240. The portable power supply 100B may include additional components besides those described and shown in this invention. For example, the portable power supply 100B may include additional power output sections 250 (e.g., both AC and DC), a display, etc.

[0045] Figure 2CAn example electronic device 100 in the form of a power tool 100C is shown. In the illustrated embodiment, the power tool 100C is a handheld core drill. The power tool 100C may include different types of indoor and outdoor, handheld or mounted power tools, such as drill bits / drives, saws, hammer drills, lighting equipment, grinders, etc. The power tool 100C includes a housing 255 that houses a motor and receives a removable power tool battery pack 240. The removable power tool battery pack 240 corresponds to a battery system 110, and the motor corresponds to an AC load 120. A bidirectional power converter 130 is coupled between the removable power tool battery pack 240 and the motor. The bidirectional power converter 130 converts DC power from the removable power tool battery pack 240 into AC power for the motor. In some embodiments, the power tool 100C may further include a power cord for receiving AC power. In these embodiments, the bidirectional power converter 130 also converts AC power from a power input or from the motor into DC power for charging the removable power tool battery pack 240. The power tool 100C may include additional components in addition to those described and shown in this utility model.

[0046] Figure 3 A simplified block diagram of an inverter 300, which may be included in a bidirectional power converter 130, is shown. In the illustrated embodiment, the inverter 300 includes six switches arranged in an inverter bridge configuration. The switches include three high-side switches 310A, 310B, and 310C electrically connected between the positive terminal 320A of the battery system 110 and the AC power source or load 120. The switches also include three low-side switches 310D, 310E, and 310F electrically connected between the negative terminal 320B of the battery system 110 and the AC power source or load 120. The plurality of switches 310A-F are controlled by a controller using a gate driver to convert DC power from the battery system 110 into AC power for the AC load 120.

[0047] In one embodiment, the plurality of switches 310A-F comprises metal-oxide-semiconductor field-effect transistors (MOSFETs). In another embodiment, the plurality of switches 310A-F comprises wide-bandgap semiconductor FETs, i.e., gallium nitride (GaN) and / or silicon carbide (SiC) based FETs. In yet another embodiment, the plurality of switches 310A-F may comprise a combination of MOSFETs and wide-bandgap semiconductor FETs.

[0048] As previously explained in this invention, electronic devices (such as electronic devices 100A, 100B, 100C) may include one or more current sensor assemblies to monitor the current of one or more components of the electronic device, for example, to allow the control system of each electronic device to determine how to control the electronic device. The current sensor assembly may be additionally or alternatively included in a bidirectional power converter 130, which is included in any or all combinations of electronic devices 100. Also as previously explained in this invention, some disclosed embodiments involve extending the measurement range of integrated trace (i.e., internal trace) type current sensor assemblies to allow the integrated trace type current sensor assembly to indicate a wider range of measured current values ​​than could otherwise be measured. Therefore, the systems, methods, and apparatuses disclosed in this invention achieve a wider current measurement range that is typically only provided by external trace type current sensor assemblies while maintaining the ease of use / installation of integrated trace type current sensor assemblies.

[0049] Figure 4A A schematic diagram of a current sensing / measuring device 400 according to a first exemplary embodiment is shown. Figure 4B The following are illustrated according to some exemplary embodiments. Figure 4A The circuit diagram / circuit board layout of the current sensing device 400. (e.g.) Figure 4A and Figure 4B As shown, the current sensing device 400 includes an integrated trace-type current sensor assembly 405 (as opposed to the external trace-type current sensor assembly previously described in this invention). The current sensor assembly 405 may include a housing / chip body 410 and an integrated electrical conductor 415 located in or on the chip body 410. The current sensor assembly 405 may also include a current sensor (not shown) located in or on the chip body 410 (e.g., an integrated current sensor). The current sensor may include one or more sensors of the same or different types, such as Hall effect sensors, tunneling magnetoresistive sensors, fluxgate magnetometers, etc. During operation of the current sensor assembly 405, current flows through the integrated electrical conductor 415, and the amount of current flowing through the integrated electrical conductor 415 is determined by the current sensor. For example, the current sensor assembly 405 may include pins 420A and 420B electrically coupled to the integrated electrical conductor 415 to allow current to flow through the integrated electrical conductor 415 and be determined by the current sensor of the current sensor assembly 405. The current sensor assembly 405 may also include additional input / output pins 425, for example, to provide a voltage supply to the current sensor, to provide an output signal indicating the measured current, etc. In some cases, the current sensor assembly 405 is a non-custom integrated circuit (IC) chip that can be installed in a variety of applications / electronic devices.

[0050] In some cases, due to limitations of the components of the current sensor assembly 405 (e.g., current limitations, temperature limitations, etc.), the current sensor assembly 405 may only be able to measure the maximum current value up to the maximum current value of the current sensor assembly. In other words, the current sensor assembly 405 has a limited range of measurable current values. However, using an external resistive element 430 connected in parallel with the integrated conductor 415 (i.e., in parallel with the current measurement path of the current sensor assembly 405) allows the current sensor assembly 405 to output a measured current value indicating a total measured current value greater than the maximum value of the current sensor assembly as explained in this invention. Therefore, as explained in this invention, the measurement range of the current sensor assembly 405 is effectively extended.

[0051] In some cases, the external resistive element 430 includes one or more resistive elements in one of a variety of configurations. Figure 4A and Figure 4B In the illustrated embodiment, the external resistive element 430 includes a resistor R P A single resistor of 430.

[0052] When the current sensor assembly 405 is used without the external resistor element 430, the total current (I) flowing through the integrated conductor 415 of the current sensor assembly 405 is compared with the total current (I) flowing through the integrated conductor 415 of the current sensor assembly 405. total Unlike the case where all measurements are taken, the use of external resistor 430 causes the total current to be distributed between external resistor 430 and integrated conductor 415 in a manner inversely proportional to the resistance of each current path. Therefore, the first current (I0) flowing through integrated conductor 415... SEN The first portion (i.e., the first part of the total current) is less than the total current and is also proportional to the total current. Therefore, the current sensor assembly 405 can effectively measure currents greater than its specified input range (i.e., values ​​greater than the maximum value of the current sensor assembly). The second current (I RP (That is, the second part of the total current) flows through the external resistive element 430. Because the resistance value (R) of the external resistive element 430... P The resistance value (R) of integrated conductor 415. SEN Since the first current is known, the amount of the first current measured by the current sensor of the current sensor assembly 405 is indicated as the total current, which is the sum of the first current and the second current. Equations 1 and 2 below represent the relationship between various current values ​​and resistance values ​​of the current sensing device 400.

[0053] Equation 1: I Total = I SEN + I RP

[0054] Equation 2:

[0055] As shown in Equation 2 above, the total current can be determined based on the amount of a first current measured by the current sensor of the current sensor assembly 405, the first resistance value of the integrated conductor 415, and the second resistance value of the external resistive element 430. Specifically, the total current can be determined using Equation 3 below.

[0056] Equation 3:

[0057] In some cases, the current sensor assembly 405 includes an electronic processor (e.g., an electronic processor integrated within the chip body 410) configured to determine the total current based on a first current quantity measured by the current sensor of the current sensor assembly 405, a first resistance value based on the integrated electrical conductor, and a second resistance value based on an external resistive element. In this case, the current sensor assembly 405 may be programmable or otherwise configured to receive an indication of the resistance value of the external resistive element 430. In other cases, the electronic processor is separate from the integrated trace current sensor assembly 405 (e.g., as part of a separate controller such as a microcontroller or another IC chip). In this case, the electronic processor may receive a measurement signal from the integrated trace current sensor assembly 405 indicating the amount of the first current measured by the current sensor of the integrated trace current sensor assembly 405. The electronic processor may use the measured first current value to determine the total current value according to Equation 3 and / or may take action based on the measured first current value and / or the determined total current value. For example, in response to determining a measured first current value and / or a determined total current value that crosses one or more current thresholds, the electronic processor may control, in some way, the electronic device 100 in which the current sensing device 400 is located or a component of the electronic device 100.

[0058] As explained above, the electronic processor does not need to determine the total current value before taking action. Instead, the measured first current value itself indicates the total current, even if the total current is not specifically determined / calculated. Therefore, compared to the current sensor assembly 405 itself (i.e., without the external resistive element 430), the current sensing device 400 can be considered to have an extended measurement range (e.g., a larger measurement range and / or a higher maximum sensed current value) even if the total current is not specifically determined.

[0059] In some cases, a first range of current values ​​that can be determined based on current measurements from the current sensing device 400 is greater than a second range of current values ​​that can only be measured by the integrated trace-type current sensor assembly 405 when the integrated conductor 415 is not connected in parallel to the external resistor element 430. In some cases, a first range of total current values ​​that can be indicated by the current sensing device 400 is greater than a second range of total current values ​​that can only be indicated by the integrated trace-type current sensor assembly 405 (i) when the integrated conductor 415 is not connected in parallel to the external resistor element 430 (ii) such that all total current passes through the integrated conductor 415. In some cases, the maximum value of the sensed current of the current sensing device 400 is higher than the maximum value of the current sensor assembly 405 itself (i.e., without the external resistor element 430).

[0060] See Figure 4B The current sensing device 400 can be implemented on a printed circuit board (PCB). For example, an integrated trace-type current sensor assembly 405 and an external resistive element 430 can be mounted on the PCB. Figure 4B A portion of the surface of a PCB according to some exemplary embodiments is shown, on which a current sensing device 400 is implemented. For example... Figure 4B As shown, a first conductive trace 435 on the PCB is connected to a first pin 420A of the chip body 410. The first pin 420A is connected to a first end of the integrated conductor 415. The first conductive trace 435 can also be connected to a first end of an external resistor element 430. A second conductive trace 440 on the PCB is connected to a second pin 420B of the chip body 410. The second pin 420B is connected to a second end of the integrated conductor 415 opposite to its first end. The second conductive trace 440 can also be connected to a second end of the external resistor element 430 opposite to its first end.

[0061] exist Figure 4A and Figure 4B In the configuration of the current sensing device 400 shown, the current distribution between the external resistive element 430 and the integrated conductor 415 of the current sensor assembly 405 depends on the resistance (R) of the integrated conductor 415 inside the current sensor assembly 405. SEN Because the resistance (R) of the integrated electrical conductor 415 SENThe integrated conductor 415 often has a large initial resistance tolerance and / or a large temperature coefficient of resistance. In contrast, the external resistive element 430 can have a relatively small initial resistance tolerance and a relatively small temperature coefficient of resistance. A conductive element with a larger initial resistance tolerance and / or a larger temperature coefficient of resistance conducts current less constantly (i.e., has a less constant resistance value) compared to a conductive element with a smaller initial resistance tolerance and / or a smaller temperature coefficient of resistance. Therefore, assuming all other values ​​are equal, an integrated conductor 415 with a large initial resistance tolerance and / or a large temperature coefficient of resistance can negatively affect the accuracy of the current measurement obtained from the current sensing device 400. When the resistance (R) of the integrated conductor 415 inside the current sensor assembly 405 is... SEN Over time, the negative impact on the accuracy of current measurement is amplified. For example, Equation 4 below indicates the change in resistance (dR) relative to the integrated conductor 415 within the current sensor assembly 405. SEN The change in the first current (dI) was measured. SEN Due to R SEN The lower values ​​of R reduce the value of the denominator in Equation 4, therefore R at these lower values SEN The change caused the measured first current (I) SEN Significant changes.

[0062] Equation 4:

[0063] To reduce the resistance (R) of the integrated conductor 415 inside the current sensor assembly 405 SEN The potential negative impact on the accuracy of the first current measurement can be addressed by using methods such as... Figure 5A and 5B The additional external resistor element 505 is shown and explained below.

[0064] Figure 5A A schematic diagram of a current sensing device 500 according to a second exemplary embodiment is shown. Figure 5B The following are illustrated according to some exemplary embodiments. Figure 5A The circuit diagram / board layout of the current sensing device 500 is shown below. Many components of the current sensing device 500 are the same as or similar to the components of the same name in the current sensing device 400. For the sake of brevity, these components will not be explained in detail again, but the above explanation of these components and related components (e.g., electronic processor) in the current sensing device 400 applies to the components of the same name in the current sensing device 500.

[0065] like Figure 5A and Figure 5B As shown, the current sensing device 500 is similar to Figure 4A and Figure 4BThe current sensing device 400, in addition to the first external resistor element 430, also includes a second external resistor element 505 connected in series with the integrated conductor 415, such that the first external resistor element 430 is connected in parallel with the series combination of the second external resistor element 505 and the integrated conductor 415. The first current (I) to be measured by the current sensor of the current sensor assembly 405 is... SEN The current flows through the second external resistive element 505 and the integrated electrical conductor 415.

[0066] In some cases, the second external resistive element 505 includes one or more resistive elements in one of a variety of configurations. Figure 5A and Figure 5B In the illustrated embodiment, the second external resistive element 505 includes a resistor R S A single resistor, 505.

[0067] In some cases, the resistance characteristics of the second external resistive element 505 (and the first external resistive element 430) are selected to be superior to those of the integrated conductor 415. For example, the second external resistive element 505 includes a first tolerance of initial resistance that is smaller / narrower than the second tolerance of the initial resistance of the integrated conductor 415. The second external resistive element 505 may additionally or alternatively include a first temperature coefficient of resistance that is lower than the second temperature coefficient of resistance of the integrated conductor 415. When the resistance characteristics of the second external resistive element 505 are selected in this way, assuming all other values ​​are equal, the accuracy of the current sensing device 500 is improved relative to the resistance (Rt) of the integrated conductor 415 due to initial tolerance or temperature, compared to when the second external resistive element 505 is not used. SEN The changes in resistance (dR) are less sensitive. For example, Equation 5 below indicates the change in resistance relative to the integrated conductor 415 within the current sensor assembly 405. SEN The change in the first current (dI) was measured. SEN Compared to Equation 4, which represents a current sensing device 400 without a second external resistive element 505, the denominator of Equation 5 becomes larger because the resistance (R) of the second external resistive element... S ) is positive, which makes it possible because R SEN The change caused by the measurement of the first current (I) SEN The change is smaller than that of the current sensing device 400 without the second external resistor element 505.

[0068] Equation 5:

[0069] Furthermore, since the total resistance of the external resistive elements 430 and 505 and the integrated conductor 415 in the current sensing device 500 is greater than the total resistance of the external resistive elements 430 and the integrated conductor 415 in the current sensing device 400 (assuming all other values ​​are equal), the impact of resistance variations of any conductor in the current sensing device 500 (e.g., integrated conductor 415, conductive traces 440, 510 and 515 of the PCB, which tend to have a large temperature coefficient of resistance, etc.) on the accuracy of current measurement is also reduced.

[0070] As explained above, the first accuracy of the current sensing device 500 (with the second external resistor element 505) is less sensitive to changes in the first resistance value of the integrated conductor 415 than the second accuracy of the current sensing device 400 without the second external resistor element 505.

[0071] Similar to current sensing device 400, during the operation of current sensing device 500, the total current is distributed inversely proportional to the resistance of each current path among (i) the series combination of the first external resistive element 430 and (ii) the second external resistive element 505 and the integrated conductor 415. Therefore, the first current (I0) flowing through the second external resistive element 505 and the integrated conductor 415... SEN The first portion (i.e., the first part of the total current) is less than the total current and is also proportional to the total current. Therefore, the current sensor assembly 405 can effectively measure currents greater than its specified input range (i.e., the maximum value of the current sensor assembly). The second current (I... RP (That is, the second part of the total current) flows through the external resistive element 430. This is because the resistance value (R) of the first external resistive element 430... P The resistance value (R) of the second external resistor element 505 S The resistance value (R) of integrated conductor 415. SEN Since the first current is known, the amount of the first current measured by the current sensor of the current sensor assembly 405 is indicated as the total current as the sum of the first current and the second current. Equations 6 and 7 below represent the relationship between various current values ​​and resistance values ​​of the current sensing device 500.

[0072] Equation 6:

[0073] Equation 7:

[0074] As shown in Equation 7 above, the total current can be determined based on the amount of a first current measured by the current sensor of the current sensor assembly 405, the first resistance value of the integrated conductor 415, the second resistance value of the first external resistive element 430, and the third resistance value of the second external resistive element 505. Specifically, the total current can be determined using Equation 8 below.

[0075] Equation 8:

[0076] See Figure 5B And similar to current sensing device 400, current sensing device 500 can be implemented on a PCB. For example, an integrated trace-type current sensor assembly 405, a first external resistor element 430, and a second external resistor element 505 are mounted on the PCB. Figure 5B A portion of the surface of a PCB according to some exemplary embodiments is shown, on which a current sensing device 500 is implemented. For example... Figure 5B As shown, a first conductive trace 510 on the PCB is connected to a first terminal of a first external resistor element 430 and a first terminal of a second external resistor element 505. A second conductive trace 515 on the PCB can be connected between (i) a second terminal of the second external resistor element 505 opposite to its first terminal and (ii) a first pin 420A of the chip body 410. The first pin 420A is connected to the first terminal of the integrated conductor 415. A third conductive trace 440 on the PCB is connected to a second pin 420B of the chip body 410. The second pin 420B is connected to a second terminal of the integrated conductor 415 opposite to its first terminal. The third conductive trace is also connected to a second terminal of the first external resistor element 430 opposite to its first terminal.

[0077] Other electrical connections besides the conductive traces on the PCB can be used to connect the circuit elements disclosed in this invention. In some cases, the components of the current sensing devices 400 and 500 can be arranged differently to achieve the same or similar results. For example, the second external resistor element 505 can be arranged in series with the integrated conductor 415 between the second pin 420B and the conductor, instead of being connected between the first pin 420A and the conductor (i.e., the conductive trace 440 is modified into two separate traces, and the conductive traces 505 and 510 are modified into a single conductive trace).

[0078] Similar to the current sensing device 400 described above, the current sensing device 500 may be implemented in at least one of the following groups: a power tool battery pack, a power tool, a portable power supply, a first bidirectional power converter included in the power tool battery pack, a second bidirectional power converter included in the power tool, a third bidirectional power converter included in the portable power supply, and combinations thereof.

[0079] Although the present invention has been described in detail with reference to certain preferred embodiments, variations and modifications may occur within the scope and spirit of one or more independent aspects of the present invention. Various features and advantages are set forth in the appended claims.

Claims

1. A current sensing device, characterized in that, include: Integrated trace-type current sensor assembly, including Chip body, An integrated electrical conductor, located in or on the chip body, wherein a first current flows through the integrated electrical conductor, and A current sensor, located in or on the chip body, wherein the current sensor is configured to measure the amount of the first current; and An external resistive element is connected in parallel with the integrated electrical conductor, wherein a second current flows through the external resistive element; The total current, which is the sum of the first current and the second current, is determined based on the amount of the first current measured by the current sensor, the first resistance value of the integrated electrical conductor, and the second resistance value of the external resistive element; and The first range of current values ​​that can be determined based on current measurement results from the current sensing device is greater than the second range of current values ​​that can only be measured by the integrated trace-type current sensor assembly when the integrated electrical conductor is not connected in parallel to the external resistive element.

2. The current sensing device as described in claim 1, characterized in that, The device further includes an electronic processor configured to determine the total current based on the amount of the first current measured by the current sensor, the first resistance value of the integrated electrical conductor, and the second resistance value of the external resistive element.

3. The current sensing device as described in claim 2, characterized in that, The electronic processor is integrated within the chip body.

4. The current sensing device as described in claim 2, characterized in that, The electronic processor is separate from the integrated trace current sensor assembly, and wherein the electronic processor receives from the integrated trace current sensor assembly a measurement signal indicating the amount of the first current measured by the current sensor.

5. A current sensing device, characterized in that, include: Integrated trace-type current sensor assembly, including Chip body, An integrated electrical conductor located in or on the chip body, wherein a first current flows through the integrated electrical conductor, and A current sensor, located in or on the chip body, wherein the current sensor is configured to measure the amount of the first current; and An external resistive element is connected in parallel with the integrated electrical conductor, wherein a second current flows through the external resistive element; The amount of the first current measured by the current sensor is indicated as the total current, which is the sum of the first current and the second current.

6. The current sensing device as described in claim 5, characterized in that, The first range of the total current value that can be indicated by the current sensing device is greater than the second range of the total current value that can only be indicated by the integrated trace-type current sensor assembly when the integrated conductor is not connected in parallel to the external resistive element such that all of the total current passes through the integrated conductor.

7. The current sensing device as described in claim 5, characterized in that, The integrated trace-type current sensor assembly and the external resistive element are mounted on a printed circuit board; The first conductive trace on the printed circuit board is connected to a first pin of the chip body, and the first pin is connected to a first end of the integrated electrical conductor. The first conductive trace is connected to the first end of the external resistive element; The second conductive trace on the printed circuit board is connected to a second pin of the chip body, and the second pin is connected to a second end of the integrated electrical conductor opposite to the first end of the integrated electrical conductor; and The second conductive trace is connected to a second end of the external resistive element opposite to the first end of the external resistive element.

8. The current sensing device as described in claim 5, characterized in that, It further includes an electronic processor configured to determine the total current based on the amount of the first current measured by the current sensor, a first resistance value of the integrated electrical conductor, and a second resistance value of the external resistive element.

9. The current sensing device as claimed in claim 8, characterized in that, The electronic processor is integrated within the chip body.

10. The current sensing device as claimed in claim 8, characterized in that, The electronic processor is separate from the integrated trace current sensor assembly, and wherein the electronic processor receives from the integrated trace current sensor assembly a measurement signal indicating the amount of the first current measured by the current sensor.

11. The current sensing device as claimed in claim 5, characterized in that, It further includes a second external resistive element connected in series with the integrated electrical conductor, such that the external resistive element is connected in parallel to the series combination of the second external resistive element and the integrated electrical conductor, wherein the first current flows through the second external resistive element.

12. The current sensing device as claimed in claim 11, characterized in that, The second external resistor element includes: A first tolerance of the initial resistance, wherein the first tolerance of the initial resistance is less than a second tolerance of the initial resistance of the integrated electrical conductor; and The first temperature coefficient of resistance is lower than the second temperature coefficient of resistance of the integrated electrical conductor.

13. The current sensing device as claimed in claim 11, characterized in that, Compared to the second accuracy of the current sensing device without the second external resistive element, the first accuracy of the current sensing device is less sensitive to changes in the first resistance value of the integrated electrical conductor.

14. The current sensing device as claimed in claim 11, characterized in that, The integrated trace-type current sensor assembly, the external resistor element, and the second external resistor element are mounted on a printed circuit board; The first conductive trace on the printed circuit board is connected to the first end of the external resistor element and the first end of the second external resistor element; The second conductive trace on the printed circuit board is connected between the second end of the second external resistor element, which is opposite to the first end of the second external resistor element, and the first pin of the chip body, wherein the first pin is connected to the first end of the integrated electrical conductor; The third conductive trace on the printed circuit board is connected to a second pin of the chip body, and the second pin is connected to a second end of the integrated electrical conductor opposite to the first end of the integrated electrical conductor; and The third conductive trace is connected to a second end of the external resistive element opposite to the first end of the external resistive element.

15. The current sensing device as claimed in claim 5, characterized in that, The current sensing device is implemented in at least one of the following groups: a power tool battery pack, a power tool, a portable power supply, a first bidirectional power converter included in the power tool battery pack, a second bidirectional power converter included in the power tool, a third bidirectional power converter included in the portable power supply, and combinations thereof.

16. A current sensing device, characterized in that, include: Integrated trace-type current sensor assembly, including Chip body, An integrated electrical conductor located in or on the chip body, wherein a first current flows through the integrated electrical conductor, and A current sensor, the current sensor being located in or on the chip body, wherein the current sensor is configured to measure the amount of the first current; A first external resistor element is connected in parallel with the integrated electrical conductor, wherein a second current flows through the first external resistor element; and A second external resistor element is connected in series with the integrated electrical conductor, such that the first external resistor element is connected in parallel with the series combination of the second external resistor element and the integrated electrical conductor, wherein the first current flows through the second external resistor element; The total current, which is the sum of the first current and the second current, is determined based on the amount of the first current measured by the current sensor, the first resistance value of the integrated electrical conductor, the second resistance value of the first external resistive element, and the third resistance value of the second external resistive element.

17. The current sensing device as claimed in claim 16, characterized in that, The second external resistor element includes: A first tolerance of the initial resistance, wherein the first tolerance of the initial resistance is less than a second tolerance of the initial resistance of the integrated electrical conductor; and The first temperature coefficient of resistance is lower than the second temperature coefficient of resistance of the integrated electrical conductor.

18. The current sensing device as claimed in claim 16, characterized in that, Compared to the second accuracy of the current sensing device without the second external resistive element, the first accuracy of the current sensing device is less sensitive to changes in the first resistance value of the integrated electrical conductor.

19. The current sensing device as claimed in claim 16, characterized in that, The integrated trace-type current sensor assembly, the first external resistor element, and the second external resistor element are mounted on a printed circuit board; The first conductive trace on the printed circuit board is connected to the first end of the first external resistor element and the first end of the second external resistor element; The second conductive trace on the printed circuit board is connected between the second end of the second external resistor element, which is opposite to the first end of the second external resistor element, and the first pin of the chip body, wherein the first pin is connected to the first end of the integrated electrical conductor; The third conductive trace on the printed circuit board is connected to a second pin of the chip body, and the second pin is connected to a second end of the integrated electrical conductor opposite to the first end of the integrated electrical conductor; and The third conductive trace is connected to a second end of the first external resistor element opposite to the first end of the first external resistor element.

20. The current sensing device as claimed in claim 16, characterized in that, The current sensing device is implemented in at least one of the following groups: a power tool battery pack, a power tool, a portable power supply, a first bidirectional power converter included in the power tool battery pack, a second bidirectional power converter included in the power tool, a third bidirectional power converter included in the portable power supply, and combinations thereof.

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