Hall-Element Current Sensor Assembly With Guided Board Positioning
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Solution Overview
Problem
Existing current sensors face challenges in efficiently housing components without damaging them due to complex assembly processes and potential interference between components during assembly.
Innovation Solution
The implementation of positioning means and path regulating means within a casing to ensure components are housed in a specified position without interference, allowing for a simple and damage-free assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are housed in a casing using a complex assembly process, then manufacturing cost is reduced, but workability deteriorates and component damage risk increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning the coil and magnetic sensor in their final locations within the casing before assembling other components. The circuit board is also pre-positioned with the magnetic sensor mounted on it. This preliminary arrangement eliminates the need for complex rotation and repositioning operations during assembly, improving workability while maintaining cost effectiveness.
2Adaptability or versatility
If components are temporarily disposed in the gap during assembly, then assembly flexibility is improved, but component interference and damage risk increase
Solution Approach 1:
The patent introduces non-magnetic spacers as intermediary elements between the magnetic core and the coil/magnetic sensor assembly. These spacers maintain the necessary gap distance while preventing direct contact and potential damage between components. The spacers act as mediators that allow flexible assembly while protecting the magnetic components from interference and damage.
3Manufacturing precision
If the circuit board is rotated during assembly, then proper positioning is achieved, but assembly complexity and damage risk increase
Solution Approach 1:
The patent employs asymmetric positioning features on the circuit board, including positioning protrusions that fit into corresponding recesses in the casing. This asymmetric design provides unique orientation references that guide the circuit board into its correct position without requiring rotation operations. The asymmetric features ensure precise positioning while simplifying the assembly process.
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 approach facilitates easy and damage-free housing of components by guiding them along a regular path, preventing interference and ensuring proper positional relationships, thereby enhancing assembly efficiency and reducing component damage.
Implementation Method 1
a core disposed in the housing and penetrated by the measurement object and generating a magnetic field by the current flowing in the measurement object
Implementation Method 2
a hall sensor disposed in the housing and measuring the magnetic field applied by the core
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A current sensor (100) being an electronic device includes a structure of: a case body (102) which houses a plurality of components (104a, 104b, 110, 112) inside; magnetic cores (104) housed in the case body (102) as the components and formed with gaps (104c) on the way of an annular magnetic path; a circuit board (110) housed in the case body (102) with the magnetic cores (104) and formed with a circuit to sense a current to be sensed by using output signals from Hall elements (112) to be disposed in the gaps (104c); gap position ribs (102b) which position and dispose the circuit board (110) in a specified position where a positional relationship not to cause interference between the Hall elements (112) and the other components is held, in a housed state in the case body (102); and the case body (102) and the circuit board (110) which permit housing of the circuit board (110) into the case body (102) from an outside, only through a regular path not to cause the interference between the Hall elements (112) and the other components.