Segmented Flux Concentrator for Current Sensor Stray Field Rejection

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Solution Overview

Problem

Current sensors without circular magnetic flux concentrators suffer from insufficient sensitivity, signal-to-noise ratio, and increased susceptibility to stray external magnetic fields.

Innovation Solution

A current sensor design utilizing two magnetic field sensing elements with different maximum response axes, positioned proximate to a magnetic flux concentrator, which influences the direction of the magnetic fields, and a differencing circuit to generate a difference signal related to the electrical current, effectively reducing sensitivity to stray fields.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a circular magnetic flux concentrator is used, then sensitivity and signal-to-noise ratio are improved, but device complexity and cost increase

Engineering Contradiction:
ImprovesensitivityVSAvoiddevice complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent divides the magnetic flux concentrator into multiple segments arranged in a specific pattern (e.g., U-shapes, C-shapes, or other geometric configurations) rather than using a complete circular ring. This segmentation reduces the total amount of magnetic material needed while maintaining the flux concentration effect, thereby improving sensitivity without requiring a full circular structure.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent places magnetic flux concentrator segments at specific locations around the conductor where they most effectively concentrate magnetic flux toward the sensing element. Rather than uniformly distributing material around the entire circle, the design optimizes local placements to achieve maximum flux concentration with minimum material, reducing device complexity while maintaining measurement precision.

Inventive Principle:
Principle #3Local quality

2Measurement precision

If a circular magnetic flux concentrator is used, then signal-to-noise ratio is improved, but manufacturing cost increases

Engineering Contradiction:
Improvesignal-to-noise ratioVSAvoidmanufacturing cost
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

By segmenting the flux concentrator into discrete geometric shapes that can be independently manufactured and positioned, the patent reduces manufacturing complexity and material costs. The segmented design allows for simpler fabrication processes compared to creating a complete circular ring structure.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent employs magnetic flux concentrator segments made from cost-effective magnetic materials in simplified geometric configurations. These segmented structures use less material than a complete circular concentrator, directly reducing manufacturing costs while maintaining the necessary signal-to-noise ratio through optimized flux concentration at critical locations.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Device complexity

If no magnetic flux concentrator is used, then device complexity is reduced, but sensitivity and signal-to-noise ratio become insufficient

Engineering Contradiction:
Improvedevice complexityVSAvoidsensitivity
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The segmented flux concentrator design provides the necessary magnetic flux concentration to achieve adequate sensitivity, but in a simplified form that reduces device complexity compared to a complete circular structure. The segments are strategically positioned to concentrate flux where needed without requiring a full环形 configuration.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent employs magnetic flux concentrator segments with specific geometric configurations (such as U-shapes or C-shapes) that create effective flux concentration pathways. These geometric designs concentrate magnetic flux in three-dimensional space around the conductor, achieving the necessary sensitivity enhancement without requiring a complete circular ring structure.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

4Measurement precision

If no magnetic flux concentrator is used, then sensitivity to stray external magnetic fields is reduced, but sensitivity to sensed current becomes insufficient

Engineering Contradiction:
Improvesensitivity to sensed currentVSAvoidsensitivity to stray fields
Core Design Contradiction:
Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent positions magnetic flux concentrator segments at specific locations where they can concentrate the magnetic flux generated by the sensed current while being less effective at concentrating stray external magnetic fields. This selective placement creates local flux concentration zones that enhance sensitivity to the target current while naturally providing some rejection of external interference.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The segmented flux concentrator design often employs asymmetric geometric configurations (such as U-shapes or C-shapes oriented in specific directions) that are optimized to concentrate flux from the sensed current. This asymmetric arrangement provides directional sensitivity enhancement for the target current while being less effective at concentrating magnetic flux from external stray fields approaching from other directions.

Inventive Principle:
Principle #4Asymmetry

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 enhances sensitivity and signal-to-noise ratio while effectively reducing the influence of external stray magnetic fields, providing a more efficient and robust current sensing solution.

Implementation Method 1

a magnetic flux concentrator for redirecting a magnetic field through two magnetic field sensing elements

Methodology Applied
Scientific EffectMagnetic flux concentration: Magnetic Field

Implementation Method 2

a magnetic field generated by an electrical current flowing through a conductor

Methodology Applied
Scientific EffectMagnetic field generation from electrical current: Electromagnetic Induction

Implementation Method 3

the first magnetic field sensing element having a first maximum response axis, the first magnetic field sensing element operable to generate a first signal responsive to a first magnetic field

Methodology Applied
Scientific EffectMagnetic field sensing: Hall Effect

Implementation Method 4

a differencing circuit operable to subtract the first and second signals to generate a difference signal related to the electrical current

Methodology Applied
Scientific EffectSignal differencing:

Data Source

PatentUS11513141B2Current sensor having a flux concentrator for redirecting a magnetic field through two magnetic field sensing elements
Publication Date: 2022.11.29 ALLEGRO MICROSYSTEMS LLC
  • US11513141B2 patent drawing
  • US11513141B2 patent drawing
  • US11513141B2 patent drawing

AI summary

A method can use a current sensor that can include a magnetic flux concentrator along with first and second magnetic field sensing elements disposed proximate to the magnetic flux concentrator, wherein the magnetic flux concentrator is operable to influence a direction of first and second magnetic fields at the first and second magnetic field sensing elements, respectively, the first and second magnetic fields resulting from an electrical current passing through a conductor, the first and second magnetic field sensing elements operable to generate first and second signals, respectively, in response to the first and second magnetic fields, respectively, wherein the current sensor can also include a differencing circuit operable to subtract the first and second signals to generate a difference signal related to the electrical current.