Busbar Through-Hole Current Sensor for Magnetic Interference Control
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Solution Overview
Problem
Current sensors face challenges in accurately measuring current due to manufacturing errors affecting symmetry and alignment of conductor sections and magnetic sensors, leading to difficulty in suppressing external magnetic fields and complicating the manufacturing process.
Innovation Solution
A current sensor design that inserts a sensing section into a through-hole of a busbar, allowing for magnetic field detection without direct mounting, thereby reducing external magnetic field interference and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two magnetic sensors are mounted directly on the busbar at specified positions to detect magnetic fields, then measurement accuracy is improved, but the manufacturing process becomes complicated and manufacturing precision requirements increase
Solution Approach 1:
A non-magnetic plate is introduced as an intermediary component between the busbar and the magnetic sensors. The plate includes a through-hole through which the busbar passes, and the magnetic sensors are mounted on the plate rather than directly on the busbar. This intermediary structure simplifies the manufacturing process by providing a convenient mounting surface for the sensors while maintaining the required measurement accuracy, as the plate can be precisely positioned relative to the busbar through the through-hole alignment.
2Measurement precision
If two conductor sections are arranged symmetrically with an aperture to maximize magnetic flux density gradient, then measurement accuracy is improved, but manufacturing precision requirements increase due to symmetry constraints
Solution Approach 1:
The conductor structure is segmented into two separate conductor sections (first and second conductor sections) that are positioned on opposite sides of the aperture. The non-magnetic plate with the through-hole provides a reference structure that allows these segmented conductor sections to be positioned relative to each other without requiring perfect symmetry. Each conductor section can be independently positioned, and the differential measurement approach still achieves high accuracy while reducing the overall manufacturing precision requirements for symmetry.
3Measurement precision
If magnetic sensors are positioned at specific locations to suppress external magnetic fields, then measurement accuracy is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The non-magnetic plate with the through-hole serves multiple functions: it provides a mounting surface for the magnetic sensors, maintains the positional relationship between the busbar and sensors, and facilitates the assembly process. This multi-functional component enables the magnetic sensors to be positioned at the optimal locations for suppressing external magnetic field interference while keeping the manufacturing process simple and straightforward, as the plate can be easily attached to the busbar through the through-hole.
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 design effectively suppresses external magnetic field effects while maintaining high measurement accuracy by canceling errors through differential sensing, even with slight positional shifts.
Implementation Method 1
a sensing section that is capable of detecting a magnetic field generated by flow of the current to be measured through the busbar
Data Source
AI summary
A current sensor according to the present invention that measures a current to be measured flowing through a busbar includes a sensing section that is capable of detecting a magnetic field generated by flow of the current to be measured through the busbar. The current flowing in the busbar is measured based on a change in the magnetic field detected by the sensing section. The sensing section is inserted into a through-hole of the busbar that penetrates the busbar in a thickness direction of the busbar, and a direction of an axis of detection of the magnetic field performed by the sensing section extends in a direction of the insertion into the through-hole.