Coreless Current Sensor Module With Insulated Bus Bar Spacing
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Solution Overview
Problem
Existing current sensor modules face challenges in securing insulation and preventing measurement errors due to high voltages and temperature-induced stress when closely positioned to bus bars, which can affect accurate current measurement.
Innovation Solution
Incorporating an insulator with gaps between the current sensor and bus bars to maintain insulation and reduce stress from temperature changes, while using coreless current sensors to measure magnetic fields without a magnetic core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the current sensor is closely positioned to the bus bar to improve measurement accuracy, then measurement precision is improved, but insulation reliability deteriorates due to high voltage risks
Solution Approach 1:
The patent introduces an insulator as an intermediary component positioned between the current sensor and the bus bar. This insulator maintains electrical isolation while allowing the sensor to remain in close proximity to the bus bar for accurate magnetic field detection, thus resolving the contradiction between measurement precision and insulation reliability
2Measurement precision
If the current sensor is closely positioned to the bus bar to improve measurement accuracy, then measurement precision is improved, but stress from temperature changes increases affecting durability
Solution Approach 1:
The insulator serves as a thermal buffer between the current sensor and the bus bar. It reduces the transmission of thermal stress from the high-temperature bus bar to the current sensor, allowing close positioning for accurate measurement while protecting the sensor from excessive thermal stress
Solution Approach 2:
The patent utilizes materials with appropriate thermal expansion coefficients for the insulator and support structure. This allows the components to expand and contract harmoniously with temperature changes, minimizing differential thermal stress on the current sensor while maintaining measurement accuracy
3Reliability
If an insulator is introduced to maintain insulation and reduce stress, then reliability is improved, but device complexity increases
Solution Approach 1:
The insulator is designed to perform multiple functions simultaneously: providing electrical insulation between the sensor and bus bar, reducing thermal stress transmission, and serving as a mechanical support structure. This multi-functionality improves reliability while minimizing the increase in 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
Ensures reliable current measurement by securing insulation and minimizing stress on the current sensor, thereby improving measurement accuracy and durability.
Implementation Method 1
a first current sensor which is mounted on a first surface of the support member and includes at least one magnetoelectric conversion element which outputs a signal corresponding to a magnitude of a magnetic field
Implementation Method 2
a first bus bar through which a current generating a magnetic field detected by the first current sensor flows
Data Source
AI summary
A coreless current sensor module includes: a support member; a first current sensor which is mounted on a first surface of the support member and includes at least one magnetoelectric conversion element which outputs a signal corresponding to a magnitude of a magnetic field; an insulator which surrounds at least the first current sensor in a spaced-apart state as viewed in a first direction intersecting the first surface and at least partially overlaps with the first current sensor as viewed in a second direction extending along the first surface; and a first bus bar through which a current generating a magnetic field detected by the first current sensor flows, in which at least one of the insulator or the support member is present between the first current sensor and the first bus bar.