Current Sensor With Gapped Core and Parallel Detection
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Solution Overview
Problem
Current detectors face issues with variations in detection accuracy due to unstable Hall element positions, difficulty in downsizing, and thickness reduction due to the need for matching end surfaces with detection surfaces, and are prone to detection errors from vibration and noise.
Innovation Solution
A current sensor design with a core member and magnetic detector that allows for parallel detection of magnetic fields, secured on a substrate, with adjustable gaps and busbar insertion, and includes redundant detection elements to stabilize position and reduce noise interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the end surfaces of the core member are matched in size to the detection surface of the Hall element, then detection accuracy is improved, but the thickness of the current detector increases
Solution Approach 1:
The patent changes the detection direction from perpendicular to the detection surface (traditional Hall element configuration) to parallel with the detection surface. This dimensional change allows the magnetic field to be detected along the thickness direction of the core member, eliminating the need for large end surfaces and reducing the overall thickness of the detector while maintaining detection accuracy
2Device complexity
If the Hall element position is not stabilized, then device complexity is reduced, but detection accuracy varies due to vibration
Solution Approach 1:
The patent replaces the mechanical positioning system (holding members and precise mechanical alignment) with a substrate-based mounting system. The Hall element is mounted on a substrate that provides stable positioning through surface mounting techniques, eliminating complex mechanical holding structures while ensuring stable detection accuracy even under vibration conditions
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 achieves stable detection accuracy, miniaturization, and reduced thickness by stabilizing the magnetic detector's position, reducing vibration-induced errors, and enhancing noise resistance.
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
Figure 1A~1B
Figure 2
Figure 3
AI summary
A current sensor 1 includes a core member 2 having a first gap 22 between end surfaces 21 and having a circular shape through which a busbar 4 is insertable, the core member 2 being configured to concentrate a magnetic field generated when a current to be measured passes through the busbar 4, and a magnetic detector 3 configured to detect the magnetic field concentrated by the core member 2. The magnetic detector 3 has a detection surface 31 that detects the magnetic field and detects the magnetic-field components parallel to the detection surface 31, and the detection surface 31 is disposed parallel to the direction in which the two end surfaces 21 defining the first gap 22 face each other. Accordingly, the current sensor 1 is suitable for miniaturization and reduced thickness.