Hall Sensor Housing for Precise Air-Gap Current Measurement
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Solution Overview
Problem
Current current measurement methods in electrical conductors using shunt designs require invasive electrical connections, making precise, non-intrusive measurements challenging, especially when the printed circuit board is distant from the magnetic core's air gap, leading to potential bending and misplacement of elongated Hall sensors.
Innovation Solution
A Hall sensor housed in a sensor protection component with a housing, which includes a frustoconical opening for centering and snap fits for secure mounting on the printed circuit board, reducing mechanical stress and ensuring accurate positioning within the air gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the Hall sensor is elongated to reach the air gap from a distant PCB, then non-intrusive current measurement is enabled, but the sensor becomes prone to bending and misplacement during handling and assembly
Solution Approach 1:
The Hall sensor is divided into two functional parts: a sensitive portion (first part) that extends into the air gap for measurement, and a body portion (second part) that remains mounted on the PCB. This segmentation allows the sensitive part to be long enough for non-intrusive measurement while the body part remains short and robust, reducing bending risks during assembly.
Solution Approach 2:
A sensor protection component is introduced as an intermediary structure between the Hall sensor and the external environment. This protection component houses the Hall sensor, provides mechanical support, and prevents bending during handling and assembly, thereby improving positioning reliability without affecting measurement capability.
2Reliability
If the Hall sensor is housed in a protection component, then mechanical stress and bending are reduced, but the device complexity increases
Solution Approach 1:
The sensor protection component is integrated with the existing magnetic core structure. The protection component's housing is positioned around the Hall sensor and combines with the magnetic core assembly, creating a unified structure that provides protection without requiring separate mounting steps or additional complex components.
3Measurement precision
If the PCB is located at a long distance from the air gap, then non-intrusive measurement is achieved, but the Hall sensor requires elongation which increases bending risk
Solution Approach 1:
The Hall sensor is segmented into a long sensitive portion that reaches the air gap and a short body portion mounted on the PCB. This allows the sensor to achieve non-intrusive measurement capability while the short body portion remains easy to handle and assemble, overcoming the difficulty associated with fully elongated sensors.
Solution Approach 2:
The sensor protection component acts as an intermediary that facilitates assembly by providing a housing structure that guides and protects the Hall sensor during installation. This makes the assembly process easier by reducing the risk of bending the elongated sensitive portion while maintaining the required measurement capability.
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 solution allows for precise, non-intrusive current measurement by protecting the Hall sensor from mechanical stress and ensuring accurate placement, enhancing measurement reliability and reducing the risk of bending during handling and assembly.
Implementation Method 1
Thanks to the use of the Hall sensor, a non-intrusive measure may be carried out by introducing a portion of the Hall sensor sensitive to magnetic field into the air gap of a magnetic core surrounding the conductor.
Data Source
AI summary
Electrical device including a printed circuit board, a sensor mounted on the printed circuit board and projecting from the PCB, and a sensor protection component including a housing in which is housed the sensor.