High-Current Connector Layout for Coreless Differential Current Sensing
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Solution Overview
Problem
Core-based magnetic current sensors face disadvantages such as high cost, complex assembly, inefficiencies, inaccuracies due to hysteresis and non-linearity, saturation effects, weight, and size issues, while coreless sensors lack sufficient flux density and face challenges in implementing differential sensing in EMI-polluted environments, leading to increased manufacturing costs and design complexity.
Innovation Solution
A power connector with a conductive frame, extension structure, and cap structure that defines a connector volume, incorporating a magnetic current sensor to generate a sensor signal based on a defined magnetic field produced by a current constriction region, allowing for differential magnetic field sensing without the need for a ferrous core, thereby enhancing sensitivity and robustness against EMI.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If core-based magnetic current sensors are used, then measurement precision is improved through flux density amplification, but device complexity and manufacturing cost increase due to ferrous core assembly
Solution Approach 1:
The patent removes the ferrous core from the magnetic sensor assembly, extracting only the essential sensing function. The coreless design eliminates the need for complex core assembly while maintaining measurement capability through direct flux density detection by Hall effect sensors positioned near the current-carrying conductor.
Solution Approach 2:
The connector housing serves multiple functions: it provides mechanical connection between power device and load, conducts electrical current, and integrates the magnetic current sensing function. This multi-functionality eliminates separate sensing components and reduces overall assembly complexity.
2Device complexity
If coreless current sensors are used to reduce complexity, then device complexity is reduced, but measurement precision deteriorates due to significantly reduced flux density at sensitive elements
Solution Approach 1:
The patent positions Hall effect sensors at specific locations where flux density is naturally concentrated - directly adjacent to the current-carrying conductor and at points where magnetic field lines are densest. This local positioning optimizes measurement precision without requiring flux concentration structures.
Solution Approach 2:
The connector housing acts as an intermediary structure that concentrates and directs magnetic flux toward the sensor elements. The conductive paths and structural features of the housing create favorable magnetic field distribution that enhances flux density at sensor positions.
3Reliability
If differential sensing is implemented in coreless sensors to improve EMI immunity, then reliability against stray fields is improved, but device complexity increases due to routing constraints
Solution Approach 1:
The patent combines the differential sensing pair into a single integrated sensor module that is directly mounted on the connector housing. This merging of the differential elements into one compact unit simplifies implementation while maintaining EMI immunity through inherent differential rejection of common-mode stray fields.
4Measurement precision
If ferrous cores are used for flux concentration, then measurement precision is improved, but weight and size increase
Solution Approach 1:
The patent extracts and eliminates the ferrous core component entirely, replacing it with a coreless sensing design. This removal eliminates the significant weight and volume associated with iron cores while achieving comparable measurement precision through direct sensor positioning and connector housing flux guidance.
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 provides a compact, cost-effective, and accurate differential current sensing mechanism that is immune to stray fields, reducing manufacturing costs and design complexity, while maintaining high sensitivity and accuracy.
Implementation Method 1
These devices sense the test current indirectly by measuring the magnetic flux density created by the test current
Implementation Method 2
A linear field probe (e.g. a linear hall sensor) measures the flux produced by the test current
Data Source
AI summary
A power connector is provided that is configured to conduct a current and includes a conductive frame including a base structure, an extension structure, and a cap structure that define a current path for the current. The base structure is configured to be coupled to a current supply for receiving the current therefrom. The cap structure is configured to be coupled to an electrical interface of a device to be supplied with the current and outputs the current from the connector to the electrical interface of the device. The extension structure is coupled to and vertically extends between the base structure and the cap structure. The extension structure includes a current constriction region that is configured to cause a defined magnetic field of the current flowing through the current constriction region at a predefined position.