Coreless Busbar Current Sensor Module With Press-Fit Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing current sensors with magnetic cores are bulky, heavy, and prone to non-linear errors, offset errors, and magnetic interference, while coreless sensors face reduced flux density and complex installation issues.
Innovation Solution
A magnetic coreless current sensor module with an electronic component encapsulated in an insulating material, connected to a busbar using press-fit elements, and an electromechanical connection apparatus for signal transmission, allowing compact, reliable, and adaptable current measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic core is used to concentrate the magnetic field for current measurement, then the measurement sensitivity is improved, but the device becomes bulky, heavy, and prone to non-linearity errors, saturation, and remanence effects
Solution Approach 1:
The patent removes the magnetic core from the current sensor design, extracting the problematic component that caused weight, bulk, and measurement errors. The sensor now operates without a magnetic core, using only the busbar's own magnetic field for measurement, thereby eliminating saturation and remanence effects while reducing weight and size.
Solution Approach 2:
The patent changes the operational parameters of the current sensor by eliminating the magnetic core, which alters the magnetic field concentration mechanism. This parameter change transforms the sensor from a core-based design to a coreless design, improving linearity and eliminating saturation while requiring compensation for reduced field concentration.
2Measurement precision
If a magnetic core is used to concentrate the magnetic field, then the measurement sensitivity is improved, but the device complexity and manufacturing precision requirements increase due to core alignment and positioning
Solution Approach 1:
The patent removes the magnetic core and associated positioning structures, significantly simplifying the device geometry. The coreless design eliminates the need for precise core alignment and positioning, reducing structural complexity and manufacturing precision requirements while maintaining measurement capability through direct detection of the busbar's magnetic field.
3Measurement precision
If a magnetic core is used, then the magnetic field is concentrated for better measurement, but non-linearity errors, saturation, and remanence effects occur
Solution Approach 1:
The patent removes the magnetic core that caused non-linearity errors, saturation, and remanence effects. The coreless design eliminates these reliability issues by directly measuring the magnetic field generated by the busbar without intermediate magnetic concentration components, ensuring linear and repeatable measurements across the full current range.
Solution Approach 2:
The patent uses the busbar itself as the magnetic field source, allowing the full magnetic field to act on the sensor without the limiting effects of core saturation. This excessive action approach ensures the sensor operates well within its linear range, improving measurement reliability.
4Strength
If conventional screw connections are used to attach the sensor to the busbar, then the connection is secure, but magnetic particles are generated through abrasion that corrupt magnetic current measurement
Solution Approach 1:
The patent replaces the screw connection mechanical system with a press-fit element system. This substitution eliminates the abrasive contact between screws and busbar that generates magnetic particles, while maintaining secure mechanical attachment. The press-fit elements insert into holes without threading, preventing particle generation that would corrupt magnetic measurements.
5Volume of moving object
If a compact current sensor design is implemented without a magnetic core, then the device size and weight are reduced, but the measurement capability must be maintained without flux concentration
Solution Approach 1:
The patent removes the magnetic core to achieve compact size, then compensates for the loss of flux concentration by optimizing the sensor's position and orientation relative to the busbar. The coreless design reduces volume significantly while maintaining measurement capability through direct detection of the busbar's magnetic field in the gap region.
Solution Approach 2:
The patent transitions from a core-based three-dimensional flux concentration approach to a surface-level magnetic field detection approach. By positioning the sensor in the gap between busbar surfaces and detecting the magnetic field in this region, the design achieves compactness while maintaining measurement precision through optimized spatial arrangement.
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, lightweight, and error-resistant current sensor module that maintains consistent performance over time, suitable for retrofitting various busbar sizes and environments, with reduced magnetic interference and simplified installation.
Implementation Method 1
an electronic component which is configured for the measurement of current... for the measurement of an electric current flowing in a busbar
Data Source
AI summary
A magnetic coreless current sensor module for measuring an electric current flowing in a busbar, wherein the current sensor module comprises an electronic component which is configured for the measurement of current, an electrically insulating encapsulation, in which the electronic component is at least partially encapsulated, wherein the electrically insulating encapsulation comprises at least one connecting hole for connecting to the busbar, and at least one press-fit element for connecting the encapsulation to the busbar using the introduction of the at least one press-fit element into the at least one connecting hole of the electrically insulating encapsulation and into at least one further connecting hole of the busbar.