A current sensor core

Abstract

The present invention relates to a current sensor core (1) which enables the current of three phases compatible with DC-AC converters used in electric vehicles to be measured. A current sensor core (1) wherein the reading error and possible noise are minimized, and which enables the current of three phases compatible with DC- AC converters used in electric vehicles to be measured is realized by means of the invention. The current sensor core (1) comprises a compact nested structure.

Description

[0001] DESCRIPTION

[0002] A CURRENT SENSOR CORE

[0003] Technical Field

[0004] The present invention relates to a current sensor core which enables the current of three phases compatible with DC-AC converters used in electric vehicles to be measured.

[0005] Background of the Invention

[0006] In electric vehicles, energy is stored as direct current (DC) and converted into alternating current (AC) for driving the motor. The said conversion is achieved by DC-AC converters (inverters). The torque required to drive the motor is determined by the level of the alternating current. The alternating current should be properly read in order to be able to drive the motor with the required torque levels. In the state of art, the reading of the alternating current at the inverter output is performed by a current sensor. Cores are used in order for current sensors to be able to read the phase currents. The magnetic field generated in the cores provides current values to the system via an integrated current sensor. It is important to design the cores specifically and compatible with the inverters in order to be able to perform an accurate current measurement.

[0007] In the state of art, the mounting of the current sensor core must be compatible with the inverter and be easily mountable. The position of the sensor in the core must not change and remain constant during shaking and vibrations. Such a shift may cause a change in the magnetic field and cause the current to be read incorrectly. On the other hand, the current sensor must be able to easily read the maximum current level that needs to be measured for the inverter via the core. It should be able to work at these levels for a long time without reaching saturation. The core saturated at high currents will cause the current value at that level to be read incorrectly after a while. At the same time, the reading error and offset values at low currents must also be at a level that does not cause errors in motor control.

[0008] For this reason, today, there is a need for solutions wherein the reading error and possible noise are minimized by enabling the current of three phases compatible with an inverter used for electric vehicles to be measured by overcoming the above- mentioned problems and which do not require the core to be replaced during busbar replacements.

[0009] The Chinese patent document no. CN207440162U, an application included in the state of the art, discloses a current measuring system for electric vehicles. The invention subject to the said Chinese patent document provides a pair of current sensors of electric vehicle motor controller, including sensor, power harness, plug wire plug, casing. At least two sensors are placed side by side. The sensor is fixed inside the casing, power harness passes the casing, power harness one end is connected the plug wire plug, the power harness other end is connected the sensor. This solution introduces a current sensor structure that can effectively reduce the large occupation space and technical problems that are difficult to fix in the prior art.

[0010] Summary of the Invention

[0011] An object of the present invention is to realize a current sensor core which enables the reading error and possible noise to be minimized and the current of three phases compatible with DC-AC converters used in electric vehicles to be measured.

[0012] Another object of the present invention is to realize a current sensor core which can be used without being affected by busbar replacements. A further object of the present invention is to realize a current sensor core which enables a compact structure to be achieved by means of a nested mounting structure.

[0013] Detailed Description of the Invention

[0014] “A Current Sensor Core” realized to fulfd the objectives of the present invention is shown in the figures attached, in which:

[0015] Figure 1 is a perspective view of an inventive current sensor core.

[0016] Figure 2 is a perspective view of an inventive current sensor core and the IGBT (Insulated-gate Bipolar Transistor).

[0017] Figure 3 is a mounting view of an inventive current sensor core and the current sensor.

[0018] The components illustrated in the figures are individually numbered, where the numbers refer to the following:

[0019] 1. Core

[0020] 2. Body

[0021] 3. Gap

[0022] 4. Connection hole

[0023] 5. Tab

[0024] T: IGBT (Insulated-gate Bipolar Transistor)

[0025] D: Circuit Board

[0026] An inventive current sensor core (1) which enables the reading error and possible noise to be minimized and the current of three phases compatible with DC -AC converters used in electric vehicles to be measured comprises at least one body (2); three gaps (3) which are located on the body (2); enable the IGBT (T) connection of the body; and wherein the three connection lugs of the IBGT (T) are passed through for this connection; three connection holes (4) which are located on different surfaces of the gap (3) and the body (2) and wherein the connection pins on the circuit board (D) are passed through for the current sensor connection; and a plurality of tabs (5) which are located on the same surface as the connection holes (4) on the body (2) and provide connection by being passed through the holes on the current sensor circuit board (D).

[0027] The body (2) included in an inventive current sensor core (1) realizes a connection with the IGBT (T) on one surface thereof and with the current sensor circuit board (D) on the other surface thereof. For this purpose, there are three gaps (3) wherein the connection lugs for 3 phases are passed through on the surface where the IGBT (T) connection is realized and three connection holes (4) wherein the connection pins are passed through on the surface where the connection of the circuit board (D) is realized are included on the body (2).

[0028] The gaps (3) included in an inventive current sensor core (1) are of such dimensions that the plate-shaped IGBT (T) connections therein can pass through and exit therefrom. The gaps (3) are located on one surface of the body (2), while the connection holes (4) are located on the other surface of the body (2). In this way, the IGBT (T) and current sensor can be connected to the circuit board (D) together.

[0029] The connection holes (4) included in an inventive current sensor core (1) are used together with the tabs (5) for connection to the current sensor circuit board (D). The connection holes (4) enable the electrical connection of the IGBT (T) and the circuit board (D) by being located above the gaps (3). On the other hand, the tabs (5) provide a housing for the mechanical connection of the body (2) and the circuit board (D). Preferably, there are two tabs (5) located on the body (2). Industrial Application of the Invention

[0030] It is enabled to accurately read the currents flowing through the phases in order to drive and control the electric motor by the inverter by means of an inventive current sensor core (1). For this, the inventive core (1) is connected to the current sensor circuit board (D) that will accurately read the current sensor in a compatible and stable way, and the current sensor operates in compliance with the current limits and operating conditions of the motor and the inverter. For this, the inventive current sensor core (1) comprises three gaps (3) wherein the lugs pass through for IGBT (T) connection; three connection holes (4) that are connected with the gap (3) and enable the pins of the circuit board (D) to extend into the gap by passing through them; and a plurality of tabs (5) that are used for mechanical connection to the circuit board (D). The mounting is completed by connecting the motor phases and phase connection points after the said mountings are made.

[0031] On the other hand, the current sensor core (1) provides a compact structure due to its nested connection with the IGBT (T) and the circuit board (D). The reading errors and possible noises are minimized as a stable connection is ensured. A current sensor core which enables the current of three phases compatible with DC -AC converters to be measured continues to be used without being replaced during busbar replacements.

[0032] Within these basic concepts; it is possible to develop various embodiments of the inventive “A Current Sensor Core (1)”; the invention cannot be limited to examples disclosed herein and it is essentially according to claims.

Claims

CLAIMS1. An inventive current sensor core (1) which enables the reading error and possible noise to be minimized and the current of three phases compatible with DC- AC converters used in electric vehicles to be measured; characterized by at least one body (2); three gaps (3) which are located on the body (2); enable the IGBT (T) connection of the body; and wherein the three connection lugs of the IBGT (T) are passed through for this connection; three connection holes (4) which are located on different surfaces of the gap (3) and the body (2) and wherein the connection pins on the circuit board (D) are passed through for the current sensor connection; and a plurality of tabs (5) which are located on the same surface as the connection holes (4) on the body (2) and provide connection by being passed through the holes on the current sensor circuit board (D).

2. A current sensor core (1) according to Claim 1; characterized by the body (2) which realizes a connection with the IGBT (T) on one surface thereof and with the current sensor circuit board (D) on the other surface thereof.

3. A current sensor core (1) according to Claim 1 or 2; characterized by the body (2) which includes three gaps (3) wherein the connection lugs for 3 phases are passed through on the surface where the IGBT (T) connection is realized and three connection holes (4) wherein the connection pins are passed through on the surface where the connection of the circuit board (D) is realized.

4. A current sensor core (1) according to any one of the preceding claims; characterized by the gaps (3) which are of such dimensions that the plate-shaped IGBT (T) connections therein can pass through and exit therefrom.

5. A current sensor core (1) according to any one of the preceding claims; characterized by the body (2) wherein the gaps (3) are located on one surface thereof, while the connection holes (4) are located on the other surface thereof.

6. A current sensor core (1) according to any one of the preceding claims; characterized by the connection holes (4) which are used together with the tabs (5) for connection to the current sensor circuit board (D).

7. A current sensor core (1) according to any one of the preceding claims; characterized by the connection holes (4) which enable the electrical connection of the IGBT (T) and the circuit board (D) by being located above the gaps (3).

8. A current sensor core (1) according to any one of the preceding claims; characterized by the tabs (5) which provide a housing for the mechanical connection of the body (2) and the circuit board (D).

9. A current sensor core (1) according to any one of the preceding claims; characterized by the body (2) which preferably has two tabs (5) located thereon.

Images