Hall-Effect Current Sensor Pulse Feedback for Heat and Power Reduction
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Solution Overview
Problem
Current sensors used in high current or high voltage applications, such as in electric vehicles, face issues of overheating and high power consumption due to the generation of heat and increased power demands.
Innovation Solution
A current sensor with a magnetic core, air gap, and switch configuration that operates in either continuous or pulse mode based on control signals to manage heat and power consumption, using a controller unit to determine operation modes based on thresholds for temperature, current, and frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the current sensor operates in continuous mode to maintain measurement accuracy, then measurement precision is improved, but power consumption increases and temperature rises
Solution Approach 1:
The patent applies dynamics by making the operational mode of the current sensor adjustable and adaptable rather than fixed. The sensor can dynamically switch between continuous and pulse modes based on real-time monitoring of temperature and power consumption levels, allowing the system to optimize between measurement accuracy and energy efficiency depending on operating conditions
Solution Approach 2:
The patent implements periodic action through pulse mode operation, where the sensor takes periodic measurements rather than continuous ones. This allows the sensor to maintain adequate measurement capability while significantly reducing average power consumption and heat generation during normal operation, switching to continuous mode only when necessary
2Measurement precision
If the current sensor operates in continuous mode to maintain measurement accuracy, then measurement precision is improved, but temperature increases causing overheating
Solution Approach 1:
The system dynamically adjusts its operational characteristics based on real-time temperature monitoring. When temperature exceeds predetermined thresholds, the sensor automatically transitions from continuous to pulse mode, reducing heat generation while maintaining measurement capability. This dynamic adaptation prevents overheating while preserving measurement accuracy when conditions permit
Solution Approach 2:
The patent implements feedback mechanisms where temperature and power consumption are continuously monitored and fed back to control the operational mode. This closed-loop control ensures that the sensor operates in continuous mode only when temperature and power levels are within acceptable ranges, automatically switching to pulse mode when thresholds are exceeded to prevent overheating
3Use of energy by moving object
If the sensor operates in pulse mode to reduce power consumption, then power consumption is reduced, but measurement accuracy decreases
Solution Approach 1:
The patent applies parameter changes by adjusting the pulse frequency, duty cycle, and measurement intervals based on operating conditions. This allows the system to optimize the balance between power consumption and measurement accuracy - using higher frequency or longer duty cycles when accuracy is prioritized and lower frequency or shorter duty cycles when power savings are more important
4Use of energy by moving object
If the sensor operates in pulse mode to reduce power consumption, then power consumption is reduced, but temperature decreases which may affect measurement reliability
Solution Approach 1:
The system uses feedback from temperature and power consumption monitoring to intelligently control operational mode transitions. This ensures that pulse mode is activated only when it is safe to do so, maintaining measurement reliability by preventing operation in conditions that would compromise accuracy while still achieving power and heat reduction benefits
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 solution effectively reduces overheating and power consumption by dynamically adjusting the sensor's operation mode, ensuring accurate current measurement while optimizing power usage and temperature regulation.
Implementation Method 1
a magnetic transducer configured in the air gap
Implementation Method 2
an amplifier coupled to the magnetic transducer; the amplifier is configured to receive an output voltage from the magnetic transducer; and generate an amplified voltage comprising a feedback current
Implementation Method 3
a Hall-effect sensor configured in the air gap
Data Source
AI summary
A method and apparatus comprising a magnetic core, a Hall-effect sensor configured in an air gap of the magnetic core, an amplifier coupled to the Hall-effect sensor, a driver coupled to the amplifier, a secondary winding comprising (i) a wire coil that is extended around the core body and (ii) a first end coupled to the driver, and (iii) a second end coupled to a sampling resistor, a switch configured to allow a feedback current from the driver to the secondary winding, and a controller unit coupled to the switch, the controller unit configured to (i) receive a digital signal based on a sampling voltage associated with the sampling resistor, (ii) generate one or more control signals based on operating condition data that comprises at least the digital signal exceeding one or more thresholds, and (iii) transmit the one or more control signals to the switch.