Vehicle Battery Current Sensor Using a Coreless Hall Constriction
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Solution Overview
Problem
Current sensors for vehicle batteries, particularly in electric and hybrid vehicles, require redundant current measurement to ensure reliability and accuracy, but existing solutions are costly due to the use of multiple measurement principles and complex structures.
Innovation Solution
A current sensor design utilizing a Hall effect sensor without an iron core, combined with a measuring resistor, and a redundant evaluation circuit system for mutual checking and correction, allowing for a compact, cost-effective, and reliable measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a Hall effect sensor with an iron core is used to enclose the electrical conductor, then the magnetic field detection capability is improved, but the structural complexity and manufacturing effort increase significantly
Solution Approach 1:
The patent removes the iron core from the Hall effect sensor assembly, extracting the essential magnetic field detection function while eliminating the complex core structure. The Hall sensor is positioned directly against the electrical conductor without requiring an enclosing iron core, thereby simplifying the overall device structure while maintaining measurement capability
Solution Approach 2:
The electrical conductor itself serves as an intermediary element that concentrates and directs the magnetic field generated by the current flow. By positioning the Hall sensor in a recess of the conductor, the conductor's geometry acts as a natural flux concentrator, eliminating the need for an external iron core to generate or strengthen the magnetic field
2Measurement precision
If an iron core with Hall effect sensor is used for current measurement, then the measurement accuracy is improved, but the manufacturing cost and production effort increase
Solution Approach 1:
The iron core is completely removed from the design, eliminating the complex assembly steps required to position and secure the core around the conductor. The Hall sensor is simply mounted in a recess of the conductor, dramatically reducing manufacturing steps and production time
Solution Approach 2:
The Hall sensor mounting recess is integrated directly into the electrical conductor structure, merging the conductor and sensor housing into a single piece. This eliminates separate assembly steps for mounting the sensor and reduces the number of components that need to be manufactured and assembled
3Reliability
If redundant current measurement with multiple measurement principles is implemented, then the reliability is improved, but the device complexity and cost increase
Solution Approach 1:
The electrical conductor is designed to serve multiple functions simultaneously: it acts as the current-carrying element, provides the mounting structure for the Hall sensor, concentrates the magnetic field, and serves as part of the measurement circuit. This multi-functionality reduces the number of separate components needed for redundant measurement
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 design achieves high measurement accuracy and reliability with simplified production, enabling efficient detection and correction of malfunctions, while reducing structural complexity and costs.
Implementation Method 1
The first current measurement device has a Hall effect sensor. The electrical conductor has a measurement portion, with a constriction with a reduced cross section, in the region of the first current measurement device, the Hall effect sensor being arranged in this constriction.
Data Source
AI summary
A current sensor, fora vehicle battery in a vehicle, with an electrical conductor which has a first connection and a second connection for contacting a power circuit of a vehicle. The current sensor includes a first current measurement device and a second current measurement device for measuring the current flowing over the electrical conductor. An evaluation circuit receives measurement values of the first current measurement device and/or the second current measurement device to output a current measurement signal proportional to the current. The first current measurement device utilizes a Hall effect sensor disposed within a constriction with a reduced cross section of the electrical conductor.