C-Shaped Shield Plate Current Sensor Design
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Solution Overview
Problem
Current sensors face challenges in accurately measuring a wide range of currents due to magnetic saturation and increased costs associated with enlarging the gap area to prevent saturation, which affects the linearity and accuracy of current measurement.
Innovation Solution
A current sensor design featuring a C-shaped shield plate with a magneto-electronic conversion element positioned near the minimum magnetic flux density point, mounted on a wiring board and held securely within a chassis, reduces magnetic saturation and allows for accurate measurement of a wide current range without the need for large gap areas, thereby minimizing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the gap area is increased to prevent magnetic saturation, then the current measurement range is extended, but the manufacturing cost increases due to additional zonal members or plate laminations
Solution Approach 1:
The patent changes the geometric parameters of the shield plate, specifically optimizing the gap width and the curvature radius of the inner surface. By setting the gap width to 0.5-2.0mm and the curvature radius to 3-10mm, the magnetic flux density distribution is optimized to prevent saturation while maintaining a compact structure that avoids additional costly components
Solution Approach 2:
Instead of increasing the gap area to prevent saturation (conventional approach), the patent inverts the approach by optimizing the gap width to be small (0.5-2.0mm) and using the curved inner surface geometry to achieve uniform magnetic flux density distribution, thereby preventing saturation without needing a large gap area or additional zonal members
2Reliability
If the gap area is increased to maintain linearity, then magnetic saturation is prevented, but the device complexity increases due to additional zonal members or laminations
Solution Approach 1:
The patent optimizes geometric parameters including gap width (0.5-2.0mm), curvature radius (3-10mm), and shield plate thickness (1-5mm) to achieve uniform magnetic flux density distribution that prevents saturation and maintains linearity without adding structural complexity
Solution Approach 2:
The shield plate's inner surface is designed with a specific curvature radius (3-10mm) that causes magnetic flux to distribute uniformly across the gap, preventing saturation and maintaining measurement linearity without requiring additional zonal members or complex laminated structures
3Measurement precision
If the magneto-electronic conversion element is positioned in the gap, then magnetic flux density detection is maximized, but position sensitivity causes measurement inaccuracy when the element moves
Solution Approach 1:
The curved inner surface of the shield plate creates a region of uniform (equalized) magnetic flux density distribution in the gap. This equipotential-like magnetic field ensures that even if the magneto-electronic conversion element moves slightly in position, it remains in a region with consistent magnetic flux density, thereby maintaining measurement stability and accuracy
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 solution enables accurate measurement of a wide current range while preventing magnetic saturation and reducing costs by optimizing the placement and mounting of the magneto-electronic conversion element and shield plate, ensuring stable output and secure positioning of components.
Implementation Method 1
The magneto-electronic conversion element detects magnetic flux density of a magnetic field which is generated when the current flows through the conductor, and converts the magnetic flux density into an electric signal
Implementation Method 2
the core 2 shields an effect on the magnetic field from an outside
Data Source
AI summary
A current sensor which can measure accurately current of a wide range, at low cost. A C-shaped shield plate is positioned around a flow direction of a current of the bus bar. When the current flows through the bus bar, magnetic flux density of a magnetic field is generated. A magneto-electronic conversion element detects the magnetic flux density of the magnetic field, and converts the magnetic flux density into an electric signal. Furthermore, the magneto-electronic conversion element is arranged near a position where the previously measured magnetic flux density of the magnetic field, which is generated when a current flows through the bus bar, is minimized between the conductor and the shield plate.