Embedded Hall Sensor Connector for Stray Current Detection
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Solution Overview
Problem
Electrical systems, such as servers, are susceptible to electrical faults where current returns through unintended paths, causing damage and safety risks, and existing fault detection methods are inaccurate and costly to implement.
Innovation Solution
Embedding a magnetic core and Hall-effect sensor within electrical connectors to detect imbalances in supply and return currents, allowing for early fault detection and corrective measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing fault detection methods are used, then fault detection can be implemented, but the detection accuracy is low and implementation cost is high
Solution Approach 1:
The patent combines the fault detection function with the electrical connector by integrating a magnetic sensor and magnetic core directly into the connector housing. This merging eliminates the need for separate detection systems, reducing implementation cost while improving detection accuracy through direct measurement at the source of current flow.
Solution Approach 2:
The patent introduces a magnetic core as an intermediary element that concentrates and guides the magnetic field generated by current flow through the connector terminals. This intermediary enhances the magnetic field strength at the sensor location, improving detection accuracy without requiring complex detection circuitry.
2Measurement precision
If a detection system is integrated within the connector, then fault detection accuracy is enhanced and PCB space is saved, but the connector structure becomes more complex
Solution Approach 1:
The patent nests the magnetic sensor and magnetic core within the existing connector housing structure. The magnetic core is positioned to surround the current-carrying terminals, and the sensor is integrated into the housing, creating a compact nested arrangement that adds detection functionality without significantly increasing external dimensions or structural complexity.
Solution Approach 2:
The connector housing serves multiple functions: it provides mechanical support for the terminals, encloses the magnetic core, and houses the magnetic sensor. This multi-functionality reduces the need for additional structural components, maintaining simplicity while enabling integrated fault detection.
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
Enhances fault detection accuracy and reduces the likelihood of missed faults by integrating the detection system directly within the connector, saving valuable PCB space and reducing redesign costs.
Implementation Method 1
Embedding a magnetic core and Hall-effect sensor within electrical connectors to detect imbalances in supply and return currents
Implementation Method 2
A magnetic core encircles the wires 120, the terminals 110 that terminate the wires 120, or both
Data Source
AI summary
An example electrical connector includes a magnetic core embedded in the overmold and encircling conductive paths therein and a Hall-effect sensor embedded in the overmold and configured to sense a magnetic field of the magnetic core. The Hall-effect sensor generates an output that indicates whether or not the supply current flowing through the connector matches the return current flowing through the connector, and this output may be used to detect stray-current faults in which current bypasses the connector to return via alternative paths such as through a device chassis. The connector may include one or more supply wires embedded in the overmold, one or more return wires embedded in the overmold, one or more supply terminals embedded in the overmold and terminating the supply wires, and one or more return terminals embedded in the overmold and terminating the return wires. The magnetic core embedded in the overmold may encircle (a) the supply terminals or the supply wires or both, and (b) the return terminals or the return wires or both.