Coreless Bus Bar Current Sensing for Compact EV Packaging
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Solution Overview
Problem
Existing bus bar assemblies in electric vehicles face challenges due to the substantial volume and difficulty in packaging and installing current sensors, which also present thermal issues and require additional components for mitigation.
Innovation Solution
A bus bar assembly design that incorporates a coreless current sensor positioned between the bus bars, eliminating the need for magnetic cores and allowing for a more compact and efficient sensor assembly that can be easily integrated into vehicle systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional current sensors with magnetic cores are used, then current detection capability is achieved, but device volume increases and installation difficulty increases
Solution Approach 1:
The patent removes the magnetic core from the current sensor, extracting only the essential sensing functionality. This eliminates the bulky magnetic core component while maintaining current detection capability through alternative means (such as Hall effect sensing or other coreless sensor technologies), directly resolving the contradiction between measurement precision and device volume.
Solution Approach 2:
The patent replaces the traditional magnetic core mechanical structure with a coreless sensor design that uses electromagnetic fields or other physical principles for current detection. This substitution eliminates the need for substantial magnetic core components, reducing sensor volume while preserving measurement capability.
2Measurement precision
If traditional current sensors are used, then current detection is achieved, but ease of installation deteriorates due to space constraints
Solution Approach 1:
By removing the magnetic core and associated mounting structures, the sensor becomes more compact and adaptable to tight spaces within vehicle power electronics. This extraction simplifies the installation process and improves ease of operation in constrained environments.
Solution Approach 2:
The coreless sensor design creates a more universal component that can be installed in various configurations and locations within the vehicle's power electronic systems. The simplified structure allows for greater flexibility in installation scenarios.
3Measurement precision
If traditional current sensors are used, then current measurement is achieved, but thermal issues worsen requiring additional mitigation components
Solution Approach 1:
By extracting and eliminating the magnetic core, the patent removes a significant heat-generating component from the sensor assembly. This reduction in thermal load decreases the need for additional cooling components and simplifies thermal management in the power electronic system.
4Measurement precision
If traditional current sensors with magnetic cores are used, then current detection is achieved, but device complexity increases due to additional components needed
Solution Approach 1:
The patent extracts and removes the magnetic core and associated complex mounting and cooling components, leaving a simplified sensor assembly that achieves current detection through more integrated and less complex means, thereby reducing overall device complexity.
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 a more compact and efficient sensor assembly that reduces thermal issues and eliminates the need for additional components, while maintaining accurate current detection and adhering to electromagnetic compatibility (EMC) best practices.
Implementation Method 1
a coreless sensor configured to detect a current through the bus bar assembly
Data Source
AI summary
A bus bar assembly includes a first housing; a first bus bar extending through the first housing; a second bus bar extending through the first housing, the second bus bar including a second housing that defines at least one first receiver configured to engage a fastener; and a sensor assembly mounted to the receiver, the sensor assembly including a current sensor positioned between the first bus bar and the second bus bar. The sensor assembly may not include a magnetic core, and the current sensor may be a coreless sensor configured to detect a current through the bus bar assembly.