Bus Bar Current Sensing with Integrated Hall Backup Accuracy
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Solution Overview
Problem
Current sensing devices face challenges in achieving high accuracy and miniaturization, with shunt sensors experiencing power dissipation and heat generation, while Hall sensors require large cores and are less accurate in harsh environments.
Innovation Solution
A current sensing device incorporating a dual sensor configuration with a bus bar, shunt sensor, and Hall sensor, where the Hall sensor is integrated into a sensor hole in the bus bar, allowing for improved measurement accuracy and resistance to noise, with a differential signal output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shunt sensor is used for current measurement, then installation is simple and cost is low, but power dissipation occurs and heat is generated reducing measurement accuracy
Solution Approach 1:
The patent combines both shunt sensor and Hall sensor into a single current sensing device. The shunt sensor provides simple installation and low cost, while the Hall sensor provides high accuracy measurement without heat-related drift. The controller selectively uses or combines measurements from both sensors to achieve both ease of manufacture and high measurement precision.
2Loss of energy
If a Hall sensor is used for current measurement, then power loss is small, but a relatively large core must be installed increasing device size
Solution Approach 1:
The patent merges Hall sensor with shunt sensor in a compact integrated structure. The shunt sensor requires no magnetic core, eliminating the need for large magnetic components. The combination allows achieving low power loss through Hall effect measurement while maintaining compact size through the shared structural design.
3Ease of manufacture
If shunt sensor is used for high current measurement, then installation is simple, but measurement accuracy decreases due to heat generated in shunt resistor
Solution Approach 1:
The patent introduces a controller as an intermediary that receives measurements from both shunt sensor and Hall sensor. The controller selectively chooses or combines the measurement data based on operating conditions, using the Hall sensor's stable measurement to compensate for the shunt sensor's heat-induced accuracy degradation during high current measurement while maintaining installation simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The dual sensor configuration maintains measurement accuracy by utilizing a Hall sensor as a backup, enabling precise current measurement even in harsh environments and high voltages, and provides a digital signal resistant to noise.
Implementation Method 1
Hall sensors, in which a potential difference (Hall voltage) and a magnetic field are generated in the direction perpendicular to a current by the Hall effect around a conductor through which current flows
Implementation Method 2
Shut sensors convert voltage drop caused by a shunt resistor into a current and measure the current
Implementation Method 3
power dissipation occurs in the shunt resistor and heat is generated
Data Source
AI summary
The present invention relates to a current sensing device comprising: a bus bar including a plurality of low-resistance metal portions separated from each other with a resistance portion therebetween; a printed circuit board arranged below the bus bar; a plurality of fixing pins which are joined to the metal portions of the bus bar to fix the bus bar on the printed circuit board and provide a current path between the metal portions and the printed circuit board; and at least one Hall sensor module. At least a portion of the Hall sensor module is inserted into a sensor hole formed in at least one of the low-resistance metal portions of the bus bar.