Modular Connector Current Sensing With Magnetic Shielding

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Solution Overview

Problem

The limited geometric space within connectors makes it impractical to provide separate conventional current sensors for each electrical contact or wire, complicating current measurement due to close proximity and interference from external magnetic fields.

Innovation Solution

A magnetic shield integrated into the retaining frame of a modular connector system shields magnetic field sensors from external interference, allowing multiple sensors to determine current flows by superimposed magnetic fields, using Hall elements for precise measurements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If separate conventional current sensors are provided for each electrical contact, then current measurement accuracy is improved, but device complexity and space requirements increase

Engineering Contradiction:

Improvecurrent measurement accuracyVSAvoidsensor arrangement complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Multiple magnetic field sensors are integrated into a single current sensor arrangement that measures the superimposed magnetic field of multiple electrical contacts. The sensors are arranged in a compact configuration within the connector housing, combining what would traditionally require separate sensors for each contact into one unified measurement system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The current sensor arrangement is designed to measure currents in multiple electrical contacts simultaneously using a single sensor system. The magnetic field sensors detect the superimposed magnetic fields from multiple contacts, enabling one sensor arrangement to perform the function of multiple separate sensors.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Volume of moving object

If magnetic field sensors are placed close to electrical contacts, then space is optimized, but external magnetic field interference increases

Engineering Contradiction:

Improveconnector space utilizationVSAvoidexternal magnetic field interference

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

A magnetic shield is introduced as an intermediary element between the magnetic field sensors and external magnetic field sources. The shield is integrated into the connector housing and positioned to block external magnetic fields from reaching the sensors, while allowing the sensors to remain in close proximity to the electrical contacts for accurate measurement.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If multiple current sensors are installed in limited connector space, then current measurement capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvemulti-contact current measurementVSAvoidsensor assembly manufacturing

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

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 approach enables accurate current measurement with reduced complexity and cost by simultaneously shielding all sensors, optimizing space and reducing external interference, while maintaining a compact design.

Implementation Method 1

A current sensor arrangement (15) for measuring a respective current flow through electrical contacts or contact lines (L1, L2, L3) in a connector comprises several magnetic field sensors (5) each designed to measure a magnetic field strength within the connector

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Implementation Method 2

a magnetic shield (7) arranged to protect a sensing area from an external magnetic field

Methodology Applied

Scientific EffectMagnetic shielding: Magnetic Field

Implementation Method 3

using Hall elements for precise measurements

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentEP3593152B1Modular connector with current sensor arrangement and current measurement method

Publication Date: 2026.01.21 HARTING ELECTRIC STIFTUNG & CO KG

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AI summary

The present invention relates to the field of current measurement in a plug connector and, in particular, to a current sensor arrangement for measuring a particular current flow through electrical contacts or contact lines in a plug connector and to a method in connection with the measurement of a particular current flow through electrical contacts or contact lines in a plug connector. A current sensor arrangement (15) for measuring a particular current flow through electrical contacts or contact lines (L1, L2, L3) in a plug connector is proposed, having a plurality of magnetic field sensors (5) which are each designed to measure a magnetic field strength in the plug connector, and a magnetic shield (7, 7', 7'') which at least partially surrounds a continuous shielding area (A) for shielding from an external magnetic field, wherein the plurality of magnetic field sensors (5) are arranged in the shielding area (A), and the current sensor arrangement (15) is configured such that the electrical contacts or contact lines (L1, L2, L3) jointly extend through the shielding area (A).