Current Sensor Arrangement with Defined Conductor Spacing
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Solution Overview
Problem
Current sensor arrangements in high-voltage systems, such as those in hybrid vehicles, face challenges in detecting large switching currents efficiently due to the need for expensive and space-intensive measurement devices, and often require potential-free measurement methods to avoid errors from remanent magnetization and external fields.
Innovation Solution
A current sensor arrangement with a magnetic core and magnetic field sensor, where the supply conductor and arrester are guided through the interior of the magnetic core at a defined distance, allowing for magnetic field attenuation without coils, enabling the use of inexpensive soft magnetic materials and reducing remanent magnetization, and incorporating a magnetic field sensor for accurate fault current detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement devices are used for large breaking currents, then measurement accuracy is improved, but device cost and installation space increase significantly
Solution Approach 1:
The invention extracts the measurement function from complex conventional devices and implements it using a simple magnetic core with integrated Hall sensors. The magnetic core serves dual purposes: as a magnetic circuit element and as a structural housing for the sensors, eliminating the need for separate shielding and mounting components.
Solution Approach 2:
The Hall sensors are mounted directly in receptacles within the magnetic core structure itself. The magnetic core contains both the magnetic circuit path and the sensor mounting locations, creating a nested arrangement where the sensing elements are embedded within the magnetic structure.
2Productivity
If high flux density materials are used to measure large currents, then measurement range is improved, but remanent magnetization and measurement errors increase
Solution Approach 1:
The invention changes the operating parameters by using a magnetic core with specific permeability characteristics that allow large current measurement through magnetic field attenuation rather than high flux density. The defined distance between conductors creates a differential measurement approach that operates at lower flux density levels.
Solution Approach 2:
The magnetic core acts as an intermediary that attenuates the magnetic field from large currents to a level suitable for Hall sensor measurement. The core's magnetic properties transform the high-current magnetic field into a measurable signal without requiring the sensor to directly withstand high flux densities.
3Measurement precision
If separate shielding measures are added to reduce measurement errors, then measurement accuracy is improved, but device complexity and space increase
Solution Approach 1:
The magnetic core combines multiple functions: it provides the magnetic circuit for current sensing, houses the Hall sensors in integrated receptacles, and provides magnetic shielding against external fields. This merging of functions eliminates the need for separate shielding components and reduces overall device complexity.
Solution Approach 2:
The magnetic core is designed as a multi-functional component that simultaneously serves as the magnetic circuit element, the sensor mounting structure, and the shielding element. This universal design approach reduces the total number of components needed in the measurement system.
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 design results in a compact, cost-effective current sensor that can measure large currents at low flux densities, increasing measurement accuracy and usability in limited spaces, while avoiding errors from remanent magnetization and external fields, and allowing for effective detection of fault currents.
Implementation Method 1
Due to the defined distance between the supply conductor and the conductor, a defined attenuation of a magnetic field in the magnetic core is achieved
Implementation Method 2
the magnetic field sensor is provided in the interior space of the magnetic core
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a current sensor arrangement comprising a magnetic core (1) and a magnetic field sensor (2), which are arranged in a housing (3). In order to create advantageous construction conditions, according to the invention, a feed line (4) and a diverter (5) are provided, the feed line (4) and the diverter (5) are connected to the housing (3), an isolating spacer piece (6) can be arranged between the feed line (4) and the diverter (5), the magnetic core (1) has an internal space (7) through which the feed line (4) and the diverter (5) are guided, the magnetic field sensor (2) is provided in the internal space (7) of the magnetic core (1), and the feed line (4) and the diverter (5) are arranged at a defined distance to one another. In this way, large currents can be measured with a compact embodiment of the current sensor arrangement, without saturation effects occurring in the magnetic core.