Current Sensor Coil and Hall Layout to Minimize Interference
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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
The proposed solution involves a current sensor design that includes a wire coil wrapped around a core, with a pinboard and metal pins to transfer voltage signals, a holder for fixation, and a circuit board for digital output, along with a configuration that orthogonally positions Hall-effect sensors to minimize interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a Hall-effect sensor with air gap is used for current sensing, then the device complexity is reduced, but measurement precision deteriorates due to sensitivity and accuracy issues
Solution Approach 1:
The sensor is divided into two independent sensing elements: a coil-based current sensor and an open-loop current sensor. Each element handles specific current ranges independently, avoiding the interference problems of integrated designs while maintaining structural simplicity.
Solution Approach 2:
The patent positions the coil-based sensor and open-loop sensor at different spatial locations (first location and second location respectively) within the housing, using spatial separation to eliminate interference between the two sensing mechanisms while maintaining compact overall structure.
2Measurement precision
If coil windings are tightly wound to improve sensitivity, then measurement precision improves, but manufacturing precision deteriorates due to deformation or misalignment
Solution Approach 1:
The wire coil is wrapped around a core material forming a nested structure where the coil is confined within the core's geometric constraints. This nesting provides mechanical support and maintains consistent winding geometry, reducing deformation while preserving sensitivity.
Solution Approach 2:
The core material acts as an intermediary between the wire coil and the external environment, providing mechanical support and maintaining the coil's geometric integrity. This intermediary structure prevents deformation during manufacturing and operation.
3Device complexity
If coil-based and open-loop circuitries are integrated in the same location, then device complexity is reduced, but measurement precision deteriorates due to interference between circuitries
Solution Approach 1:
The sensor is divided into two independent sensing elements: a coil-based current sensor and an open-loop current sensor. Each element handles specific current ranges independently, avoiding the interference problems of integrated designs while maintaining structural simplicity.
Solution Approach 2:
The patent positions the coil-based sensor and open-loop sensor at different spatial locations (first location and second location respectively) within the housing, using spatial separation to eliminate interference between the two sensing mechanisms while maintaining compact overall structure.
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 enhances sensor performance by maintaining coil stability, reducing interference, and improving accuracy and sensitivity across a broad current range.
Implementation Method 1
a wire coil wrapped around a core... configured to receive a voltage signal from the wire coil
Implementation Method 2
a Hall-effect sensor coupled to the open-loop current sensor element... configured to generate a first output based on operation of the open-loop current sensor element
Data Source
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.