Current Sensor Bus Bar Asymmetric Recess Design
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Solution Overview
Problem
Current sensors that measure current based on magnetic fields generated by bus bars often experience increased electrical resistance due to the shape of adjacent bus bars, leading to inefficiencies in detection and mechanical strength.
Innovation Solution
The design includes a first and second bus bar with detection and adjustment recesses, allowing for a smaller detection recess depth and reducing electrical resistance, while maintaining mechanical strength by balancing the configuration of the bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the detection recess depth is reduced to suppress electrical resistance increase, then electrical resistance is improved, but the detection precision may deteriorate
Solution Approach 1:
The bus bar structure employs asymmetric recess design where the detection recess is positioned at a specific depth from one surface while an adjustment recess is positioned at a different depth from the opposite surface. This asymmetric configuration allows the detection recess to be shallow enough to maintain low electrical resistance while the adjustment recess compensates for detection precision by enabling precise positioning of the magneto-electric conversion element relative to the current flow path.
Solution Approach 2:
The invention changes the geometric parameters of the bus bar by introducing two recesses at different depths and positions. The detection recess depth is optimized to minimize electrical resistance increase, while the adjustment recess depth and position are optimized to maintain detection precision. This parameter optimization resolves the contradiction between electrical resistance and detection precision.
2Measurement precision
If the bus bar shape is adjusted to reduce magnetic field influence, then measurement precision is improved, but mechanical strength may deteriorate
Solution Approach 1:
The bus bar structure applies local quality modification by creating recesses only in specific localized areas where they are needed for detection and adjustment purposes. The majority of the bus bar maintains its original solid structure to preserve mechanical strength, while the localized recesses enable precise magnetic field detection without significantly compromising overall structural integrity.
Solution Approach 2:
The bus bar is segmented into distinct functional zones: the detection recess area for magnetic field sensing, the adjustment recess area for element positioning, and the remaining solid structure for mechanical support. This segmentation allows each zone to be optimized for its specific function while maintaining overall structural strength through the preserved solid portions.
3Reliability
If the detection recess is made smaller to reduce electrical resistance, then electrical resistance is improved, but the space for magneto-electric conversion element is reduced
Solution Approach 1:
The invention transitions from a single-depth recess design to a two-dimensional recess system with detection recess and adjustment recess at different depths and positions. This dimensional expansion allows the detection recess to remain small for low electrical resistance while the adjustment recess provides additional spatial freedom for proper positioning of the magneto-electric conversion element, effectively resolving the space constraint.
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 configuration effectively suppresses the increase in electrical resistance and reduces the influence of adjacent bus bars' magnetic fields, improving the overall strength and accuracy of current measurement.
Implementation Method 1
a magneto-electric conversion element configured to detect an induction magnetic field generated due to a current flowing through the bus bars
Data Source
AI summary
A current sensor includes a substrate, a first bus bar, and a second bus bar. The first bus bar has a first detection recess recessed in a square U-shape upstream in the extending direction (in the Y-direction) and a first adjustment recess downstream, with a first intermediate portion therebetween. The bottom surface of the first detection recess is a first bottom surface. The first sensitive axis of a first magneto-electric conversion element, if extended toward the second bus bar, abuts the body of the second bus bar at a portion where a second adjustment recess is provided.