Current Sensor Integral Molded Shield Positioning
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Solution Overview
Problem
Current magnetic sensors for multiphase conductors face challenges in accurately positioning magnetic shields, leading to measurement errors due to sensitivity variations caused by deviations in shield placement, which complicates precise integration and housing of components.
Innovation Solution
A current sensor design that achieves high accuracy in positioning the conductor, magnetic sensor, and magnetic shield by using a configuration where the lid and case are precisely engaged, allowing integral molding of the conductor with the case and the magnetic shield with the lid, minimizing external magnetic field influence and enhancing detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnetic shields are separately molded and assembled with the case and lid, then the magnetic sensor can be housed within the case, but the lid and case cannot be positioned with high accuracy, leading to measurement errors
Solution Approach 1:
The patent merges the lid and case into a single integrally molded housing structure. The magnetic shields are then molded integrally with this unified housing, eliminating assembly errors between separate components. This combining approach resolves the positioning accuracy issue while maintaining ease of manufacture through integral molding.
Solution Approach 2:
The patent segments the housing into a positioning part and a lid part that are integrally molded together. The positioning part includes features like positioning protrusions and recesses that ensure high-precision alignment. This segmentation within integral molding allows both ease of manufacture and high positioning accuracy.
2Ease of operation
If the conductor and magnetic shield are separately positioned, then the magnetic sensor can detect the magnetic field, but sensitivity varies and causes measurement error if positions deviate
Solution Approach 1:
The conductor and magnetic shield are molded integrally together as a single unit within the housing. This integral molding ensures fixed, precise relative positioning between the conductor and magnetic shield, eliminating sensitivity variations caused by positional deviations while maintaining the detection function.
3Measurement precision
If external magnetic field blocking is enhanced by adding magnetic shields, then measurement accuracy improves, but the structure becomes more complex and difficult to assemble
Solution Approach 1:
The magnetic shields are merged with the housing and conductor into a single integrally molded structure. This eliminates the need for separate assembly steps for magnetic shields while maintaining their function of blocking external magnetic fields, thus improving measurement accuracy without increasing structural complexity.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical protection, positions the conductor and magnetic shield with high precision, and blocks external magnetic fields through integrally molded magnetic shields. This multi-functionality reduces overall structural complexity while maintaining measurement accuracy.
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 enables precise positioning and reduced measurement errors, allowing for accurate detection of the magnetic field generated by the conductor while minimizing noise from adjacent conductors, thereby improving the overall measurement accuracy and allowing for downsizing of the sensor.
Implementation Method 1
a magnetic sensor (27) that measures a magnetic field that a current to be measured generates
Data Source
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AI summary
A current sensor (1) that can perform positioning among a conductor (29), a magnetic sensor (27), and a magnetic shield (21) with high accuracy and can measure a current to be measured with high accuracy is provided. The current sensor (1) has the conductor (29) through which the current to be measured flows, the magnetic sensor (27) configured to measure an induction field that the current to be measured generates, a case (13) configured to house the conductor (29) and the magnetic sensor (27) in a state where the conductor (29) and the magnetic sensor (27) are positioned and that includes a first opening (9) that allows the magnetic sensor (27) to be inserted into a housing space (8) therethrough, an insulating lid (11) configured to cover the first opening (9) of the case (13) and includes a second opening (41) for allowing the conductor (29) to communicate with the outside of the case (13), and a lid magnetic shield (21) positioned in the lid (11).