Systems and methods for reducing heat generation and power consumption of current sensors

Abstract

To provide methods and devices that reduce heat generation and power consumption of current sensors.SOLUTION: There are provided a method and a device comprising: a magnetic core that includes (i) a core body, and (ii) an air gap along the core body; a Hall-effect sensor that is configured in the air gap; an amplifier that is coupled to the Hall-effect sensor; a driver that is coupled to the amplifier; a secondary winding that includes (i) a wire coil extending around the core body, (ii) a first end coupled to the driver, and (iii) a second end coupled to a sampling resistor; a switch that is configured to allow a feedback current from the driver to the secondary winding; and a controller unit that is coupled to the switch, and is configured to (i) receive a digital signal based on a sampling voltage associated with the sampling resistor, (ii) generate one or more control signals based on operating condition data including at least the digital signal exceeding one or more thresholds, and (iii) transmit the one or more control signals to the switch.SELECTED DRAWING: None

Description

Technical Field

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

Background Art

[0002] Current sensors are used in various industrial and automotive applications. For example, monitoring of current is essential from the viewpoints of the safety, performance, and efficiency of electric vehicles. However, current sensors tend to overheat and consume high power when used in high-current or high-voltage applications such as electric vehicles. The applicant is aware of many technical problems and difficulties associated with conventional current sensors.

Summary of the Invention

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

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

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

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

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

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

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

[0010] The foregoing example summary, as well as other exemplary objects and / or advantages of the present disclosure, and the manner in which they are achieved, are further described in the following detailed description of the invention and its accompanying drawings.

Brief Description of the Drawings

[0011] The description of the illustrated embodiments can be read in conjunction with the accompanying drawings. It will be understood that, unless otherwise specified, the elements shown in the drawings are not necessarily drawn to scale for the sake of simplicity and clarity of the figures. For example, unless otherwise specified, the dimensions of some of the elements may be exaggerated relative to other elements. Embodiments incorporating the teachings of the present disclosure are shown and described in connection with the figures presented herein.

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DETAILED DESCRIPTION OF THE INVENTION

[0012] Next, some embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings, which show some, but not all, embodiments of the present disclosure. In fact, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will satisfy the applicable legal requirements. Like numbers refer to like elements throughout.

[0013] As used herein, terms such as "front", "rear", "top", etc. are used for illustrative purposes to describe the relative position of a particular component or a part of a component in the examples provided below. Further, as will be apparent to those skilled in the art from the perspective of the present disclosure, the terms "substantially" and "approximately" indicate that the element or related description being referred to is within the accuracy of applicable engineering tolerances.

[0014] As used herein, the term "comprising" means including but not limited to and should be construed in a manner typical of its use in the patent context. The use of broader terms such as "comprises", "includes", and "having" is to be understood as supporting the narrower terms such as "consisting of", "consisting essentially of", and "comprised substantially of".

[0015] Phrases such as "in one embodiment", "according to one embodiment", and the like generally mean that the particular feature, structure, or characteristic following such phrase may be included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0016] As used herein, the word "example" or "exemplary" means "serving as an instance, case, or illustration". Any embodiment described herein as "exemplary" need not be construed as being more preferred or advantageous than other embodiments.

[0017] When this specification states that a component or feature "may include / have", "can include / have", "may include / have", "should include / have", "will include / have", "preferably includes / has", "optionally includes / has", "typically includes / has", "optionally includes / has", "for example includes / has", "in many cases includes / has", or "may include / have" (or other such words), a particular component or feature need not be included or have the feature. Such a component or feature may optionally be included in some embodiments or may be excluded.

[0018] A closed-loop current sensor may include a current measurement technique that provides galvanic isolation and electrical isolation (e.g., without electrical contact) between a primary circuit (e.g., a circuit to be measured) and a sensor output for measuring a primary current of the primary circuit.

[0019] FIG. 1 shows an exemplary current sensor 100. As shown in FIG. 1, current sensor 100 includes a closed-loop current sensor. Current sensor 100 includes a magnetic core 104 wrapped by a secondary winding 108. Current sensor 100 further includes a magnetic transducer 106 configured within an air gap of magnetic core 104. Magnetic transducer 106 is coupled to an amplifier 110. Magnetic transducer 106 is configured to generate a voltage output (e.g., a Hall voltage) in the presence of a magnetic field surrounding magnetic transducer 106 within the air gap. The magnetic field can be caused by inserting a conductor 102 carrying a primary current 112 inside magnetic core 104. The voltage output can be based on the magnetic flux density of the magnetic field surrounding magnetic transducer 106 that is proportional to primary current 112.

[0020] The voltage output generated by magnetic transducer 106 can be amplified by amplifier 110 and converted into a feedback current 116. Secondary winding 108 is coupled to amplifier 110 at a first end of secondary winding 108, receives feedback current 116 such that secondary winding 108 can generate a magnetic field that opposes the magnetic field associated with primary current 112, and thereby generates a secondary current 114 at a second end of secondary winding 108 such that the following condition is generated. I P N P =I S N s Equation 1 Here, I P may represent primary current 112, I S may represent secondary current 114, N P may represent the number of primary windings associated with conductor 102, N Scan represent the number of secondary windings 108. Thus, the primary current 112 can be determined based on the derivation of the secondary current 114. A sampling resistor 118 including a known resistance value is coupled to the second end of the secondary winding 108. The secondary current 114 receives the sampling voltage 120 across the sampling resistor 118 and can be determined by using Ohm's law (e.g., V = IR). The primary current 112 can be determined based on the secondary current 114 using Equation 1.

[0021] Heat can be generated in the sampling resistor 118 as a by-product of receiving the secondary current 114. The amount of heat generated in the sampling resistor 118 can be proportional to the square of the number of amperes of current and the resistance value according to Joule's law. Thus, the greater the primary current 112, the greater the secondary current 114 and the associated heat output in the sampling resistor 118 can be. Therefore, a larger secondary current 114 may require greater power consumption by the amplifier 110 to generate the feedback current 116. Overheating and high power consumption are generally parameters that are desirable to be monitored and minimized in applications such as electric vehicles.

[0022] Various exemplary embodiments of the present disclosure overcome such technical problems and difficulties in current sensors and provide various technical advancements and improvements. According to various examples of the present disclosure, components of an exemplary current sensor for improving current sensor performance are disclosed. In some embodiments, a closed-loop current sensor includes a switch configured to either open or close the circuit of the closed-loop current sensor based on thermal and power consumption conditions and requirements. In some embodiments, the switch is configured to operate in either continuous mode or pulse mode, for example, by a controller unit, based on one or more thresholds and / or one or more optimization goals. In some embodiments, the one or more thresholds include a primary current threshold, a temperature threshold, and a primary current frequency threshold. In some embodiments, the one or more optimization goals include optimal power consumption adjustment, optimal heat generation adjustment, or overall adjustment.

[0023] Figure 2 shows an exemplary current sensor 200 according to various embodiments of the present disclosure. The current sensor 200 includes a closed-loop sensor that includes a magnetic transducer 206 (e.g., a Hall effect sensor) within an air gap along a core body of a magnetic core 204. The magnetic core 204 may include a ferromagnetic material such as a nanocrystalline material and a permalloy material (e.g., a toroidal core). In some embodiments, the magnetic core 204 has a shape that includes a ring portion and an internal void, known colloquially as a torus or a doughnut. The internal void of the magnetic core 204 may be configured for detecting a primary current 212 carried by a conductor 202 that can generate a magnetic flux detectable by the magnetic transducer 206.

[0024] The magnetic transducer 206 is coupled to an amplifier 210 (e.g., an operational amplifier). A voltage output (e.g., a Hall voltage) may be generated by the magnetic transducer 206 based on the magnetic flux detected by the magnetic transducer. The amplifier 210 may receive the voltage output from the magnetic transducer 216 and generate an amplified voltage signal that includes a feedback current 216. The feedback current 216 may be received at a first end of a secondary winding and driven through the secondary winding 208. The secondary winding 208 may include a wire coil that extends around a core body of the magnetic core 204. In some embodiments, the secondary winding 208 includes a helical coil of wire wound around the outside of the magnetic core 204. For example, the secondary winding 208 may have N s turns around the magnetic core 204. The secondary winding 208 may include a copper wire or any conductor suitable for conducting an electric current.

[0025] The feedback current 216 received by the secondary winding 208 can generate a magnetic field that opposes and cancels out the magnetic flux generated by the primary current 212, thereby resulting in a secondary current 214 at the second end of the secondary winding 208 that is proportional to the primary current 212. A sampling resistor 218 (e.g., a shunt resistor) is coupled to the second end of the secondary winding 208. The secondary current 214 can be determined by receiving a sampling voltage 220 across the sampling resistor 218 and converting the sampling voltage 220 into a digital signal that can be used to determine the value of the secondary current 214 based on the known resistance value of the sampling resistor 218. The secondary current 214 can be used to derive and determine the primary current 212.

[0026] The current sensor 200 further includes a switch 222 configured between the amplifier 210 and the secondary winding 208. The switch 222 opens and closes a circuit path (e.g., between the amplifier 210 and the secondary winding 208) that enables the feedback current 216 to be transmitted from the amplifier 210 to the secondary winding 208, thereby being configured to switch the operation (e.g., on or off) of the current sensor 200. According to various embodiments of the present disclosure, the switch 222 is configured to operate in either a continuous mode or a pulse mode based on, for example, a control signal received from a controller unit. In some embodiments, the current sensor 200 is configured to operate in the continuous mode when a higher measurement accuracy (e.g., an alternating current (AC) associated with the sampling voltage 220) is desired. In some other embodiments, the current sensor 200 is configured to operate in the pulse mode when a lower power consumption or a lower operating temperature is desired. Examples of the continuous mode control signal and the pulse mode control signal that can be transmitted and received by the switch 222 are shown in FIGS. 3A and 3B.

[0027] Figure 3A shows an exemplary continuous mode control signal according to various embodiments of the present disclosure. As shown in Figure 3A, switches configured to switch the operation of a current sensor (e.g., switch 222) can be controlled via a control signal that includes a "closed" value or an "open" value associated with a closed switch state or an open switch state, respectively. According to various embodiments of the present disclosure, the closed switch state comprises a switch in a closed position, thereby turning "on" or enabling (e.g., closing the circuit) the current sensor (e.g., current sensor 200). Conversely, the open switch state comprises a switch in an open position, thereby turning "off" or disabling (e.g., opening the circuit) the current sensor. As shown in Figures 3A and 3B, the "closed" value includes a non-zero value and the "open" value includes a zero value. However, in other embodiments, the "closed" value may include a zero value and the "open" value may include a non-zero value. The "closed" value and the "open" value can be arbitrarily specified and are not limited to the values disclosed herein.

[0028] As further shown in Figure 3A, the continuous mode control signal includes a steady "closed" value over a given period. As shown in Figure 3A, the steady "closed" value can be received by the switch, during which the current sensor associated with the switch is instructed to operate in continuous mode. During continuous mode, the steady "closed" value may enable the output from the amplifier 210 (e.g., feedback current 216) to be continuously transmitted to the secondary winding 208 and may enable continuous operation and continuous reading of the current sensor 200 to determine the secondary current 214.

[0029] FIG. 3B shows an exemplary pulse mode control signal according to various embodiments of the present disclosure. As shown in FIG. 3B, the pulse mode control signal includes alternating “closed” and “open” values over a given period. As shown in FIG. 3B, the alternating “closed” and “open” values may be received by a switch, during which a current sensor associated with the switch is instructed to operate in pulse mode. During the pulse mode, the switch associated with the current sensor transitions between an open position and a closed position, enabling the output from amplifier 210 (e.g., feedback current 216) to be periodically transmitted to secondary winding 208, thereby enabling periodic operation and periodic reading of current sensor 200 to determine secondary current 214.

[0030] FIG. 4A is a block diagram of an exemplary current sensor device 400A according to various embodiments of the present disclosure. Current sensor device 400A includes a magnetic core 402 and a Hall effect sensor 404 configured within an air gap along the core body of magnetic core 402. Inserting a conductor material carrying primary current 410 into an internal void defined by magnetic core 402 can cause a magnetic flux detectable by Hall effect sensor 404. Hall effect sensor 404 can generate a voltage output (e.g., Hall voltage) proportional to the strength of the magnetic flux proportional to the amount of primary current 410. The voltage output from Hall effect sensor 404 can be amplified by amplifier 406 to generate an amplified voltage used by driver 408 to drive a feedback current through secondary winding 412 from a first end of secondary winding 412 to a second end of secondary winding 412. Secondary winding 412 is wound around a portion of the magnetic core such that zero magnetic flux can be achieved when the feedback current is driven through secondary winding 412.

[0031] The sampling resistor 422 is configured in series at the second end of the secondary winding 412. A voltage signal can be obtained from both ends of the sampling resistor 422 (e.g., in parallel) and amplified by the amplifier 414. The amplified voltage from the amplifier 414 can be converted by the analog-to-digital converter 416 into a digital voltage signal suitable for input to the controller unit 418. The controller unit 418 may include one or more combined programmable logic circuits (complex programmable logic device: CPLD), microprocessor, multi-core processor, coprocessing entity, application-specific instruction-set processor (ASIP), microcontroller, and / or controller.

[0032] Furthermore, the controller unit 418 may be embodied as one or more other processing devices or circuits. The term circuit may refer to an overall hardware embodiment or a combination of hardware and computer program products. Therefore, the controller unit 418 may be embodied as an integrated circuit, application specific integrated circuit (ASIC), field programmable gate array (FPGA), programmable logic array (PLA), hardware accelerator, other circuits, etc.

[0033] Thus, as will be appreciated, the controller unit 418 can be configured for a particular use, or can execute instructions stored in a volatile or non-volatile medium or otherwise accessible to the controller unit 418. Thus, regardless of whether it is constituted by hardware or a computer program product, or a combination thereof, the controller unit 418 can perform steps or operations according to embodiments of the present disclosure when configured accordingly.

[0034] According to various embodiments of the present disclosure, the digital voltage signal includes the (sampling) voltage acquired across the sampling resistor 422. Given the known value of the sampling resistor 422, the controller unit 418 can receive the digital voltage signal from the analog-to-digital converter 416 and determine the secondary current to determine the value of the primary current 410. Thus, the controller unit 418 can be configured to determine the primary current 410 based on the voltage acquired across the sampling resistor 422.

[0035] The power supply voltage switch 420A is coupled between the amplifier 406 and the controller unit 418. In some embodiments, the controller unit 418 can configure the operating mode of the current sensor device 400A by transmitting a control signal to the power supply voltage switch 420A. The power supply voltage switch 420A is coupled to the power supply voltage of the amplifier 406 and can be controlled by the controller unit 418 to switch the amplifier 406 on / off (e.g., via a continuous mode control signal and a pulse mode control signal).

[0036] FIG. 4B is a block diagram of an alternative and exemplary current sensor device 400B according to various embodiments of the present disclosure. As shown in FIG. 4B, a power supply voltage switch 420B is coupled between a driver 408 and a controller unit 418 to configure the operating mode of the current sensor device 400B. In some embodiments, the controller unit 418 may configure the operating mode of the current sensor device 400B by transmitting a control signal to the power supply voltage switch 420B. The power supply voltage switch 420B is coupled to the power supply voltage of the driver 408 and may be controlled by the controller unit 418 to switch the driver 408 on / off (e.g., via a continuous mode control signal and a pulse mode control signal).

[0037] FIG. 4C is a block diagram of another alternative current sensor device 400C according to various embodiments of the present disclosure. As shown in FIG. 4C, an analog switch 420C is configured between a driver 408 and a secondary winding 412 to configure the operating mode of the current sensor device 400C. In some embodiments, the controller unit 418 may configure the operating mode of the current sensor device 400C by transmitting a control signal to the analog switch 420C. The analog switch 420C may be controlled by the controller unit 418 to open and close the path between the driver 408, which is used to drive the feedback current to the secondary winding 412, and the secondary winding 412 (e.g., via a continuous mode control signal and a pulse mode control signal).

[0038] In some embodiments, the controller unit 418 may determine an operating mode that constitutes any one of the current sensor devices 400A, 400B, and 400C based on the temperature of components such as the sampling resistor 422. As further shown in FIGS. 4A, 4B, and 4C, the current sensor devices 400A, 400B, and 400C further include a temperature sensor 424. The temperature sensor 424 may be configured to monitor the temperature of the sampling resistor 422. The temperature sensor 424 may generate a data signal representing the temperature of the sampling resistor 422. The signal generated by the temperature sensor 424 may be transmitted and received by the controller unit 418 to determine whether the temperature of the sampling resistor 422 exceeds a temperature threshold. In some exemplary embodiments, the controller unit 418 may configure the current sensor devices 400A, 400B, and 400C to operate in a pulse mode based on the determination that the sampling resistor 422 is operating at a temperature that exceeds the temperature threshold.

[0039] According to various embodiments of the present disclosure, one or more of the current sensor devices 400A, 400B, or 400C operate in either continuous mode or pulse mode based on one or more operating thresholds. In some embodiments, when the primary current determined by one or more of the current sensor devices 400A, 400B, or 400C (based on the determination and derivation of the secondary current) is higher than a defined threshold, one or more of the current sensor devices 400A, 400B, or 400C can be configured by a processing device such as the controller unit 418 to operate in pulse mode to reduce power consumption. In some other embodiments, when the operating temperature (determined using, for example, the temperature sensor 424) is higher than a temperature threshold, one or more of the current sensor devices 400A, 400B, or 400C are configured by the processing device to operate in pulse mode to reduce heat generation. In some additional embodiments, when the frequency of the primary current, including AC current, is determined by one or more of the current sensor devices 400A, 400B, or 400C to be higher than a threshold, one or more of the current sensor devices 400A, 400B, or 400C are configured by the processing device to operate in continuous mode, thereby providing a sufficient sampling rate to ensure an accurate determination of the primary current.

[0040] Referring now to FIG. 5, this is an exemplary flow diagram illustrating an exemplary method for controlling a current sensor according to some exemplary embodiments of the present disclosure. Note that each block of the flowchart, and combinations of blocks in the flowchart, can be implemented by various means such as hardware, firmware, circuits, and / or other devices associated with the execution of software including one or more computer program instructions. For example, one or more of the steps / operations described in FIG. 5 can be embodied by computer program instructions that are stored by a non-transitory memory of an apparatus adopting an embodiment of the present disclosure and can be executed by a processor component within the apparatus (such as, but not limited to, the controller unit 418). For example, these computer program instructions can instruct the processor component to function in a specific way such that the instructions stored in the computer-readable storage memory create a product and its execution implements the functions specified in the flowchart blocks.

[0041] In FIG. 5, the exemplary method 500 can be executed by a computing device associated with a current sensor (as illustrated and described herein, for example). At step 502, operating condition data associated with the current sensor is received. In some embodiments, the operating condition data includes temperature data, a current measurement value, or a current frequency value. The temperature data can be associated with the temperature of one or more components within the current sensor, such as a sampling resistor at which a voltage reading is obtained (for example, to determine a secondary current and derive / determine a primary current based on the secondary current). The current measurement value can be associated with the determined secondary current or the derived / determined primary current. The current frequency value can be associated with the frequency of the primary current including the AC current to be derived / determined (for example, the rate at which the current changes direction per second).

[0042] In some embodiments, following step 502, the exemplary method proceeds to step 504 where the operating condition data is analyzed to determine or detect whether one or more thresholds have been exceeded. In some exemplary embodiments, the one or more thresholds may include a primary current threshold TH_IP, a temperature threshold TH_temp, or a primary current frequency threshold TH_freq.

[0043] In some embodiments, following step 504, if the thresholds have not been exceeded, the operating condition data may continue to be received and monitored via steps 502 and 504 with respect to exceeding one or more thresholds.

[0044] In some embodiments, following step 504, if one or more thresholds have been exceeded, the exemplary method proceeds to step 506 where an operating mode is determined based on the one or more exceeded thresholds. For example, if the primary current determined by a current sensor is higher than a primary current threshold (e.g., 600 A), the current sensor may be configured to enter a pulse mode to reduce power consumption. In another example, if the temperature of the current sensor (or its components) is higher than a temperature threshold (e.g., 158°F or 70°C), the current sensor may be configured to enter a pulse mode to reduce heat generation. In yet another example, if the primary current frequency (e.g., the frequency of the primary current including an AC current) is higher than a frequency threshold (e.g., 400 Hz), the current sensor may be configured to enter a continuous mode that can capture a primary current operating at the primary current frequency to provide detection accuracy.

[0045] In some embodiments, determining the operating mode further includes determining an optimization goal. The optimization goal can be determined when a plurality of thresholds are exceeded. In some embodiments, one or more of the excess thresholds can be prioritized when determining which operating mode the current sensor should operate in. For example, the current sensor can be configured in pulse mode to reduce power consumption and current sensor temperature, but measurement accuracy can be prioritized over power consumption and / or current sensor temperature. That is, the current sensor can be configured in continuous mode based on the primary current frequency exceeding a frequency threshold, even though it exceeds a power consumption and / or current sensor temperature threshold.

[0046] In some other embodiments, one or more of the thresholds further comprise one or more safety thresholds. The safety threshold can include a threshold that is prioritized over a non-safety threshold. For example, the primary current threshold TH_IP, the temperature threshold TH_temp, or the primary current frequency threshold TH_freq can include a non-safety threshold. In some exemplary embodiments, the safety threshold includes a safety temperature threshold or an overcurrent threshold that is prioritized over the primary current frequency threshold TH_freq. Thus, when the safety temperature threshold or the overcurrent threshold is exceeded, the current sensor can be configured in pulse mode or in a mode where the switch state of the current sensor is configured in the open position.

[0047] FIG. 6 represents an exemplary timing diagram for optimizing power consumption according to some exemplary embodiments of the present disclosure. Optimizing power consumption can include monitoring the determined primary current and primary current frequency. Optimizing power consumption can further include configuring the current sensor to operate in either pulse mode or continuous mode based on whether the determined primary current and / or primary current frequency exceeds the primary current threshold TH_IP and / or the primary current frequency threshold TH_freq, respectively.

[0048] As shown in FIG. 6, the current sensor is configured in continuous mode based on (i) the determined primary current not exceeding the primary current threshold TH_IP and (ii) the primary current frequency not exceeding the primary current frequency threshold TH_freq (e.g., before T0, between T1 and T2, and after T5). If only the determined primary current exceeds the primary current threshold TH_IP, the current sensor can be configured to operate in pulse mode (e.g., between T0 and T1, between T2 and T3, and between T4 and T5) to reduce power consumption. When the primary current frequency exceeds the primary current frequency threshold TH_freq, the current sensor can be configured to operate in continuous mode (e.g., regardless of whether the determined primary current exceeds the primary current threshold TH_IP) so that the current sensor can capture the primary current at which it operates at the primary current frequency (e.g., between T3 and T4).

[0049] FIG. 7 shows an exemplary timing diagram for optimizing the current sensor temperature according to some exemplary embodiments of the present disclosure. Optimizing the current sensor temperature may include monitoring the current sensor temperature and the primary current frequency. Optimizing the current sensor temperature may further include configuring the current sensor to operate in either pulse mode or continuous mode based on whether the current sensor temperature and / or the primary current frequency exceed or do not exceed a temperature threshold TH_temp and / or a primary current frequency threshold TH_freq, respectively.

[0050] As shown in FIG. 7, the current sensor can be configured in continuous mode based on (i) the current sensor temperature not exceeding the temperature threshold TH_temp and (ii) the primary current frequency not exceeding the primary current frequency threshold TH_freq (e.g., before T0, after T1-2, and after T5). When only the current sensor temperature is higher than the temperature threshold TH_temp, the current sensor can be configured to operate in pulse mode (e.g., T0-T1, T2-T3, and T4-T5) to reduce heat generation. When the primary current frequency exceeds the primary current frequency threshold TH_freq, the current sensor can be configured to operate in continuous mode (e.g., regardless of whether the current sensor temperature exceeds the temperature threshold TH_temp) so that the current sensor can capture the primary current at which it operates at the primary current frequency (e.g., T3-T4).

[0051] FIG. 8 shows an exemplary timing diagram for optimizing both power consumption and current sensor temperature according to some exemplary embodiments of the present disclosure. Optimizing both power consumption and current sensor temperature may include monitoring the determined primary current, current sensor temperature, and primary current frequency. Optimizing both power consumption and current sensor temperature may further include configuring the current sensor to operate in either pulse mode or continuous mode based on whether one or more of the determined primary current, current sensor temperature, and / or primary current frequency exceed the primary current threshold TH_IP, the temperature threshold TH_temp, and / or the primary current frequency threshold TH_freq, respectively.

[0052] As shown in FIG. 8, the current sensor is configured in continuous mode based on (i) the determined primary current not exceeding the primary current threshold TH_IP, (ii) the current sensor temperature not exceeding the temperature threshold TH_temp, and (iii) the primary current frequency not exceeding the primary current frequency threshold TH_freq (e.g., before T0, between T1 and T2, between T3 and T4, and after T7). The current sensor is configured in pulse mode based on one or more of (i) the determined primary current exceeding the primary current threshold TH_IP or (ii) the current sensor temperature exceeding the temperature threshold TH_temp. When the primary current frequency exceeds the primary current frequency threshold TH_freq, the current sensor can be configured to operate in continuous mode (e.g., regardless of whether the determined primary current exceeds or does not exceed the primary current threshold TH_IP or whether the current sensor temperature exceeds or does not exceed the temperature threshold TH_temp) so as to capture the primary current at which the current sensor operates at the primary current frequency (e.g., between T5 and T6).

[0053] Returning to FIG. 5, in some embodiments, following step 506, the exemplary method proceeds to step 508, where the control signal type is determined based on the determined operating mode. According to various embodiments of the present disclosure, the control signal type can be determined to be either a continuous mode control signal or a pulse mode control signal. For example, a continuous mode control signal can be determined for continuous mode, and a pulse mode control signal can be determined for pulse mode.

[0054] In some embodiments, following step 508, if the determined control signal type is a continuous mode control signal, the exemplary method proceeds to step 510, where a continuous mode control signal is generated. In some embodiments, the continuous mode control signal includes a steady "closed" value over a given period. The generated continuous mode control signal can be received by a switch and used to control the operation of a current sensor that operates continuously to continuously obtain readings for determining the primary current. In some embodiments, following step 510, the exemplary method proceeds to step 502.

[0055] In some embodiments, following step 508, if the determined control signal type is a pulse mode control signal, an exemplary method proceeds to step 512, where a pulse mode control signal is generated. In some embodiments, the pulse mode control signal includes alternating "off" and "on" values over a given period. The generated pulse mode control signal can be received by a switch and used to control the operation of a current sensor that operates at periodic time intervals to obtain readings for determining a primary current during the periodic time intervals. In some embodiments, the phase and / or duty cycle associated with the pulse mode control signal can be adjusted to also achieve the required optimization goals (e.g., reduction of power consumption, reduction of heat generation, or both) and the required detection accuracy. In some embodiments, following step 512, the exemplary method proceeds to step 502.

[0056] It is to be understood that the present disclosure is not limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Specific terms are used herein, but unless otherwise noted, these are used only in a general and descriptive sense and not for purposes of limitation.

Claims

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

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

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

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