Conductor Structure Layout for Current Sensor Cross-Talk Reduction
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Solution Overview
Problem
Existing current sensor systems in electric vehicles face challenges in accurately measuring high currents due to conductor cross-talk errors, which are exacerbated by the proximity of multiple conductor structures and the sensitivity to environmental magnetic fields.
Innovation Solution
A conductor structure with specific notches and holes is designed to accommodate a current sensor device, utilizing magnetic field sensing elements that are differentially coupled to minimize the impact of neighboring conductor currents, allowing for precise current measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple conductor structures are placed in proximity to each other to reduce space, then space utilization is improved, but conductor cross-talk error increases
Solution Approach 1:
The conductor structure is divided into multiple segments with notches created at specific locations. These notches segment the conductor path and create distinct magnetic field zones, allowing the sensor to differentiate between adjacent conductors and reduce cross-talk error while maintaining compact spacing.
Solution Approach 2:
Magnetic field sensing elements are strategically positioned at specific locations where the magnetic field from the target conductor is strongest while the field from neighboring conductors is weakest. This local optimization of sensor placement reduces cross-talk and improves measurement precision in the compact multi-conductor arrangement.
2Measurement precision
If magnetic field sensing elements are made highly sensitive to detect current, then measurement precision is improved, but sensitivity to environmental magnetic fields increases
Solution Approach 1:
The notches in the conductor structure are designed to create specific magnetic field patterns where environmental magnetic fields affect all sensing elements equally. By using differential measurement techniques, these common-mode environmental fields are rejected while the differential signal from the target conductor current is amplified, converting the harmful environmental sensitivity into a benefit through common-mode rejection.
Solution Approach 2:
The conductor structure with notches acts as an intermediary that shapes and directs the magnetic field from the target conductor to the sensing elements. This intermediary structure enhances the desired magnetic field signal while providing geometric shielding against environmental magnetic fields, allowing high sensitivity to target current without proportional sensitivity to environmental interference.
3Object-affected harmful factors
If traditional magnetic shields are used to reduce environmental magnetic field impact, then environmental magnetic field sensitivity is reduced, but device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the need for separate magnetic shield components by integrating the magnetic field shaping and shielding functions directly into the conductor structure itself. The notches and geometric features of the conductor serve dual purposes: current conduction and magnetic field management, removing the need for additional shielding materials and reducing overall system complexity.
Solution Approach 2:
The conductor structure is designed to perform multiple functions simultaneously: it serves as the current-carrying conductor, the magnetic field shaping element, and the geometric shield against environmental magnetic fields. This multi-functionality eliminates the need for separate magnetic shield components, reducing device complexity while maintaining protection against environmental magnetic field interference.
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 system achieves high accuracy in measuring currents ranging from 100 A to over 4,000 A with reduced sensitivity to environmental magnetic fields, eliminating the need for bulky and expensive magnetic shields, and maintaining accuracy despite positional variations.
Implementation Method 1
first and second magnetic field sensing elements configured to be sensitive to a magnetic field along the second dimension when current flows through the conductor structure
Implementation Method 2
at least one of the first and second magnetic field sensing elements is one of a Hall plate element or a tunneling magnetoresistance (TMR) element
Data Source
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AI summary
Disclosed are example systems, methods, and structures for reducing conductor cross-talk error. In particular, disclosed is an example conductor structure that can conduct current and that accommodates placement of a current sensor device. The systems, methods, and structures disclosed herein may allow for multiple example conductor structures to be placed in proximity to each other, and may allow a current sensor device to measure an amount of current flowing in one of the conductor structures, while reducing the impact of any current flowing in a neighboring conductor structure on the measurement of the current sensor device. Also disclosed herein are example methods for making such a conductor structure. Further disclosed herein are example systems that incorporate both such an example conductor structure and a current sensor device, and example methods for configuring a current sensor system including both such an example conductor structure and current sensor device.