Current Sensor Coil Layout for Low-Interference Measurement
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Solution Overview
Problem
Conventional current sensors face challenges such as sensitivity and accuracy issues due to air gaps in Hall-effect sensors and interference between coil-based and open-loop circuitries, leading to performance degradation.
Innovation Solution
A current sensor design incorporating a coil current sensor element with a pinboard and holder to stabilize the wire coil and core, and arranging coil and open-loop current sensor elements in parallel but orthogonally positioned within a housing to minimize interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air gaps are present in Hall-effect sensors, then manufacturing is easier, but sensitivity and measurement accuracy deteriorate
Solution Approach 1:
The patent removes the air gap between the magnetic core and Hall-effect sensor by integrating the sensor directly onto the core surface, eliminating the harmful air gap while maintaining manufacturing feasibility through direct mounting techniques
Solution Approach 2:
The patent employs a flexible circuit board that can accommodate thermal expansion and mechanical stress, providing a cushioning effect that maintains consistent contact between the Hall-effect sensor and magnetic core under varying operating conditions, thereby preserving sensitivity
2Adaptability or versatility
If coil and open-loop current sensor elements are arranged in parallel, then measurement versatility is improved, but interference between circuitries increases
Solution Approach 1:
The patent positions the coil-based current sensor element and open-loop current sensor element in orthogonal orientations (one horizontal, one vertical), separating their magnetic field paths in different spatial dimensions to minimize mutual interference while maintaining both measurement capabilities
Solution Approach 2:
The patent assigns different functional roles to specific regions of the sensor assembly, with the coil element optimized for AC current measurement and the open-loop element for DC current measurement, allowing each component to operate in its optimal performance zone
3Stability of the object's composition
If wire coil and core are held firmly, then measurement stability is improved, but device complexity increases
Solution Approach 1:
The patent integrates the holder structure into the housing assembly, combining multiple support functions into a single integrated component that secures both the wire coil and magnetic core without requiring separate fastening mechanisms, 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
Enhances sensor performance by maintaining stability and reducing interference, thereby improving accuracy and flexibility for measuring a broad range of currents.
Implementation Method 1
The coil current sensor element includes a wire coil wrapped around a magnetic core
Implementation Method 2
sensitivity and accuracy issues due to air gaps in Hall-effect sensors
Data Source
Figure 1~2B
Figure 3A~3B
Figure 4
AI summary
Current sensors and components for measuring electrical current are provided. The current sensor component comprises a wire coil wrapped around a core and a pinboard coupled to the wire coil. The pinboard comprises a holder mounted on at least a portion of the wire coil and a pair of metal pins, wherein first ends of the pair of metal pins are coupled to the wire coil and configured to receive a voltage signal from the wire coil, and second ends of the pair of metal pins are coupled to an interface of a circuit board and configured to transfer the voltage signal from the wire coil to the circuit board.