Current Sensor Core Layout for Vibration-Stable Miniaturization
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Solution Overview
Problem
Existing current sensors face challenges in maintaining detection accuracy and stability due to vibration, difficulty in downsizing, and thickness reduction, primarily because the Hall element's position within the core member is unstable and requires matching end surfaces with detection surface areas.
Innovation Solution
A current sensor design with a core member and magnetic detector where the detection surface is parallel to the end surfaces, allowing for vibration resistance and miniaturization, and includes features like a substrate mounting, multiple gaps, and busbar integration to stabilize the detector's position and adjust magnetic field detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the Hall element is disposed in the gap of the core member with the detection surface facing the end surfaces, then the magnetic field detection accuracy is improved, but the height of the core member increases and downsizing becomes difficult
Solution Approach 1:
The detection surface of the Hall element is disposed parallel to the direction in which the two end surfaces defining the first gap face each other, rather than facing them directly. This dimensional reorientation allows the magnetic field to be detected through the side surface of the core member, eliminating the need for the detection surface area to match the end surface area, thereby reducing the height of the core member while maintaining detection accuracy
Solution Approach 2:
The orientation parameter of the detection surface is changed from perpendicular to parallel relative to the end surfaces. This parameter change allows the system to detect the magnetic field generated by current flowing through the busbar without requiring a large gap height, thus achieving downsizing while preserving measurement precision
2Reliability
If the position of the Hall element is made stable within the gap, then detection accuracy under vibration is improved, but additional structures and components are required increasing device complexity
Solution Approach 1:
By reorienting the detection surface to be parallel to the end surfaces rather than facing them, the Hall element can be positioned on the side of the core member where it is naturally stabilized by the substrate mounting structure. This eliminates the need for additional position-maintaining structures while ensuring stable detection under vibration conditions
Solution Approach 2:
The substrate serves as an intermediary that mounts the Hall element in a stable position. By placing the Hall element on the substrate with its detection surface parallel to the end surfaces, the substrate provides mechanical support and position stability without requiring complex additional structures, thereby maintaining detection accuracy under vibration
3Measurement precision
If the end surfaces area is matched to the detection surface area, then magnetic field concentration is improved, but the thickness of the current sensor increases
Solution Approach 1:
The detection is shifted from the end surface dimension to the side surface dimension. The Hall element detects the magnetic field through the side surface of the core member rather than through the end surfaces, allowing the end surfaces to be smaller without compromising magnetic field concentration or detection accuracy, thus reducing the overall thickness of the sensor
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 ensures stable detection accuracy by preventing tilt and displacement of the magnetic detector, enabling miniaturization and increased detection range, while reducing sensitivity variations and heat effects, thus enhancing reliability and durability.
Implementation Method 1
a core member having a first gap between end surfaces and having a circular shape through which a busbar is insertable, the core member being configured to concentrate a magnetic field generated when a current to be measured passes through the busbar
Implementation Method 2
a magnetic detector configured to detect the magnetic field concentrated by the core member. The magnetic detector has a detection surface that detects the magnetic field and detects the magnetic-field components parallel to the detection surface
Data Source
AI summary
A current sensor includes a core member having a first gap between end surfaces and having a circular shape through which a busbar is insertable, the core member being configured to concentrate a magnetic field generated when a current to be measured passes through the busbar, a magnetic detector configured to detect the magnetic field concentrated by the core member, and a substrate on which the magnetic detector is mounted on one side by surface mounting.