Busbar Current Sensor Assembly with Integrated Hall Effect Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing current sensor technologies for power distribution systems in the aerospace industry face challenges in accurately measuring currents without requiring precise placement and drilling holes in conductors, which complicates manufacturing and increases costs.
Innovation Solution
A busbar current sensor assembly featuring a conductive busbar member with integrated circuit boards and Hall effect sensors, where the geometry of the busbar member adjusts the magnetic field strength and eliminates the need for holes, allowing for precise current measurement without external interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a toroidal ferrite core with a slit is used to match the sensing component to the magnetic field, then the current measurement accuracy is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent extracts the magnetic field sensing function from complex toroidal ferrite core structures and implements it using simple Hall effect sensors positioned near the busbar surface. This extraction principle allows accurate magnetic field detection without requiring complex magnetic circuit structures, thereby reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The patent replaces mechanical magnetic circuit structures (ferrite cores with slits) with electronic sensing elements (Hall effect sensors). This substitution eliminates the need for complex magnetic shielding and circuit structures, simplifying the device while achieving accurate current measurement through electronic means.
2Device complexity
If shunt resistance is used in series to measure current, then the current measurement is simplified, but the power loss and heat generation increase
Solution Approach 1:
The patent substitutes resistive shunt measurement with magnetic field-based Hall effect sensing. This replacement eliminates the need for current to pass through resistive elements, thereby avoiding I²R power losses and heat generation while maintaining measurement functionality.
3Measurement precision
If current sensors are placed on opposite sides of the conductor with a hole, then the magnetic field can be reduced for proper measurement, but the manufacturing complexity and cost increase due to precise placement requirements
Solution Approach 1:
The patent extracts the sensing function from a configuration requiring holes and precise opposite-side placement, and implements it using single-sided or simplified multi-sided Hall effect sensor arrangements. This extraction eliminates the need for through-holes and precise alignment, greatly simplifying manufacturing while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces magnetic flux concentration structures or air gaps as intermediaries between the busbar and Hall effect sensors. These intermediaries enable accurate magnetic field measurement without requiring direct contact or precise positioning, thereby simplifying the manufacturing process while maintaining measurement precision.
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 solution enables efficient and accurate current measurement, reduces manufacturing complexity, and minimizes external magnetic field interference, while being compatible with existing installations.
Implementation Method 1
A busbar current sensor assembly can include a busbar member, a first insulator, a second insulator, a first circuit board, a second circuit board, a first cover, first fasteners, a second cover, and second fasteners. The busbar member can include a base with a first surface facing in a first direction and a second surface facing in a second direction, the first direction being opposite the second direction.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A busbar current sensor assembly (10) includes a busbar member (12) that includes a first cavity (60) and a second cavity (68). The second cavity is disposed opposite the first cavity. The busbar current sensor assembly also includes a first current sensor (78) disposed in the first cavity such that the first cavity at least partially surrounds the first current sensor and a second current sensor (86) disposed in the second cavity such that the second cavity at least partially surrounds the second current sensor.