Busbar Current Sensor Layout for Compact Accurate Sensing
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Solution Overview
Problem
Conventional current sensors face issues with large installation area requirements and measurement inaccuracies due to the need for vertical adjustments of magnetic sensors to adjust sensitivity, which complicates installation and increases measurement errors.
Innovation Solution
The bus bar is modified with features such as through-holes, notches, or protrusions that alter the current path, allowing the magnetic sensor to be mounted on the upper surface and adjusted in the left-right direction for sensitivity, eliminating the need for vertical adjustments and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the magnetic sensor is arranged away from the bus bar to detect the magnetic field component, then the measurement function is achieved, but the installation area increases and adjustment work becomes difficult
Solution Approach 1:
The patent changes the adjustment direction from vertical (upward/downward) to horizontal (left/right) by modifying the bus bar structure with through-holes. This dimensional change allows the magnetic sensor to be positioned closer to the bus bar while still enabling sensitivity adjustment, thereby reducing installation area while maintaining measurement accuracy.
2Measurement precision
If the magnetic sensor is arranged away from the bus bar, then the magnetic field detection is possible, but the adjustment work becomes difficult leading to measurement errors
Solution Approach 1:
The bus bar is segmented with through-holes that create distinct current path segments. These segments allow the magnetic sensor to be positioned at specific locations (left or right of the through-hole) to achieve optimal sensitivity without requiring complex vertical adjustments, thereby simplifying the adjustment process and improving measurement accuracy.
3Reliability
If the magnetic sensor is arranged away from the bus bar in the vertical direction, then the magnetic field component detection is achieved, but the sensitivity adjustment requires vertical movement increasing installation area
Solution Approach 1:
The patent transitions the sensitivity adjustment from vertical dimension to horizontal dimension by introducing through-holes in the bus bar. This allows the magnetic sensor to achieve proper sensitivity by moving left or right relative to the through-hole rather than moving vertically, thereby reducing the installation area while maintaining detection reliability.
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
This design reduces the installation area and improves measurement accuracy by facilitating easier adjustment of the magnetic sensor, reducing measurement errors, and simplifying the manufacturing process.
Implementation Method 1
a magnetic sensor (102) for detecting a magnetic field component (M) generated by the current (I) flowing through the bus bar (2, 2A, 2B, 2C, 2D)
Data Source
AI summary
A current sensor that can reduce an installation area and improve measurement accuracy has a busbar through which current to be measured flows and a magnetic sensor that detects a magnetic field component generated by the current flowing through the busbar. The busbar can have left and right through-holes which can change the flow of the current to be measured. The magnetic sensor can be mounted on the upper surface of the busbar and can be screw-fixed to the upper surface of the busbar using the left and right through-holes.