Current Sensor Segmentation for Misalignment Control

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Solution Overview

Problem

Current current sensors face accuracy degradation due to manufacturing errors and creep-related misalignments of electrical-conduction members within larger housings, leading to inefficient detection of measurement currents.

Innovation Solution

The design incorporates individual sensors with magnetoelectric converters and insulating sensor housings, where the electrical-conduction members are accommodated within smaller housings to prevent misalignment, and a wiring case with input/output wiring to maintain sensor alignment and improve detection accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If electrical-conduction members are accommodated in larger housings, then installation space is increased, but manufacturing errors and creep-related misalignments occur leading to accuracy degradation

Engineering Contradiction:

Improvehousing volumeVSAvoidcurrent detection accuracy

Core Design Contradiction:

Volume of moving objectVSMeasurement precision

Solution Approach 1:

The sensor system is divided into multiple individual sensors, each with its own insulating sensor housing. Each individual sensor is self-contained with the electrical-conduction member and magnetoelectric converter housed together in a smaller dedicated housing, preventing misalignment issues while maintaining compact installation footprint.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating sensor housing nests the electrical-conduction member and magnetoelectric converter within a compact structure. The individual sensor housing acts as an inner container that precisely positions components relative to each other, eliminating the need for larger external housings.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Measurement precision

If individual sensors with smaller housings are used, then misalignment is suppressed improving accuracy, but device complexity increases due to multiple sensors and wiring case

Engineering Contradiction:

Improvecurrent detection accuracyVSAvoidsensor system structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Multiple individual sensors are housed together within a single wiring case that provides common mounting and electrical connections. The wiring case integrates the input/output wiring for all sensors, reducing the number of separate components and simplifying installation despite the increased number of individual sensing elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The wiring case serves multiple functions: it houses multiple individual sensors, provides structural support for mounting, and integrates the electrical wiring connections for all sensors. This multi-functional design reduces overall system complexity by consolidating several functions into a single component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Measurement precision

If insulating sensor housings are used for each sensor, then misalignment and detection accuracy are improved, but manufacturing cost increases due to multiple housing components

Engineering Contradiction:

Improvesensor alignment accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The sensor system is segmented into modular individual sensors that can be manufactured independently and then assembled into the wiring case. This segmentation allows for standardized mass production of individual sensor units, reducing per-unit manufacturing costs despite the increased total number of components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Individual sensors are pre-assembled with their insulating housings in a preliminary manufacturing step, allowing for precise alignment to be built into each unit during manufacturing. This preliminary assembly ensures accurate component positioning is achieved during production rather than requiring complex alignment procedures during final system assembly.

Inventive Principle:

Principle #10Preliminary action

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 configuration effectively suppresses misalignment and enhances the detection accuracy of measurement currents, maintaining the reliability of current sensing systems.

Implementation Method 1

The magnetoelectric converter converts a measurement magnetic field caused by a flow of a measurement current in the electrical-conduction member into an electric signal

Methodology Applied

Scientific EffectMagnetoelectric conversion: Electromagnetic Induction

Data Source

PatentUS11988692B2Current sensor

Publication Date: 2024.05.21 DENSO CORP

AI summary

A current sensor includes a plurality of individual sensors and a wiring case. Each of the individual sensors includes an electrical-conduction member through which a measurement current to be measured flows, a magnetoelectric converter and an insulating sensor housing. The magnetoelectric converter converts a measurement magnetic field caused by a flow of the measurement current into an electric signal. The sensor housing accommodates the electrical-conduction member and the magnetoelectric converter therein. The wiring case is larger than the sensor housing. The wiring case includes an insulating integrated housing in which the plurality of individual sensors is fixed, and an input/output wiring disposed in the integrated housing and electrically connected to the megnetoelectric converter of each of the plurality of individual sensors.