High-Current Connector Integration for Differential Magnetic Current Sensing
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Solution Overview
Problem
Core-based magnetic current sensors face challenges such as high cost, complex assembly, inefficiencies due to hysteresis and non-linearity, saturation, weight, and size issues, as well as difficulties in implementing differential sensing in coreless designs, which affects accuracy and increases manufacturing costs.
Innovation Solution
A power connector design with a conductive frame, extension structure, and connector head that includes a current constriction region to enhance magnetic flux density, combined with a differential magnetic current sensor positioned to receive the increased flux, allowing for accurate and robust current measurement while minimizing external interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If core-based magnetic current sensors are used, then measurement accuracy is improved through flux density amplification, but device complexity, cost, and assembly complexity increase
Solution Approach 1:
The patent removes the ferrous core from the magnetic current sensor design, eliminating the field concentrator that causes hysteresis, non-linearity, and saturation effects. This extraction of the core component simplifies the device structure while maintaining measurement capability through alternative flux density enhancement methods.
Solution Approach 2:
The connector body is designed to serve multiple functions: it provides electrical connection between conductors and simultaneously acts as the mounting structure for the magnetic current sensor. The extension structure with its conductive path serves both as an electrical conductor and as a flux concentration element, eliminating the need for separate field concentrator components.
2Device complexity
If coreless current sensors are used, then device complexity and cost are reduced, but available flux density at sensitive elements is significantly reduced
Solution Approach 1:
The extension structure is designed with specific geometric features that concentrate magnetic flux locally at the sensor position. The conductive path in the extension structure creates enhanced flux density precisely where the magnetic current sensor measures, while the rest of the connector maintains its electrical connection function without unnecessary complexity.
Solution Approach 2:
The extension structure acts as an intermediary element between the current-carrying conductor and the magnetic sensor. It provides a controlled magnetic path that enhances flux density at the sensor location without requiring a ferrous core, thereby mediating between the electrical connection requirement and the measurement accuracy requirement.
3Object-affected harmful factors
If differential sensing is implemented in coreless sensors, then immunity to electromagnetic interference is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The differential sensing elements are integrated directly into the connector body structure, merging the sensing function with the electrical connection function. This integration eliminates the need for separate sensing modules and reduces overall device complexity while maintaining EMI immunity through the differential measurement approach.
Solution Approach 2:
The magnetic current sensor with differential sensing elements is nested within the connector body structure. The sensor elements are positioned within the extension structure in a way that utilizes the existing geometric features of the connector to enhance flux concentration, thereby nesting multiple functions within a single integrated structure.
4Measurement precision
If current rails are routed through field concentrators, then measurement accuracy is improved, but assembly complexity and bulk increase
Solution Approach 1:
The connector is segmented into distinct functional regions: the base structure for electrical connection, the extension structure with integrated flux concentration features, and the sensor mounting area. This segmentation allows each part to be optimized independently and assembled together, reducing overall assembly complexity compared to routing current rails through separate field concentrators.
Solution Approach 2:
The extension structure's conductive path geometry automatically provides flux concentration at the sensor location without requiring additional adjustment or complex assembly steps. The structure serves itself by using its own geometric features to enhance measurement accuracy, eliminating the need for separate field concentrator components that would increase assembly complexity.
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 provides a cost-effective, compact, and accurate current sensing method that enhances measurement precision and immunity to electromagnetic interference, addressing the limitations of core-based and coreless sensors by optimizing magnetic flux density and sensor placement.
Implementation Method 1
the extension structure includes a current constriction region that is configured to increase a magnetic flux density of a magnetic field produced by the current flowing through the current constriction region
Implementation Method 2
a magnetic current sensor arranged at a position relative to the current constriction region to receive the magnetic field having the increased magnetic flux density produced by the current flowing through the current constriction region, wherein the magnetic current sensor is configured to generate a sensor signal based on the received magnetic field
Data Source
AI summary
A power connector is provided that is configured to conduct a current. The power connector includes a base structure, an extension structure, and a connector head structure that define a current path for the current. The base structure is coupled to an output node of a primary conductor and receives the current from the primary conductor. The connector head structure is configured to output the current from the power connector to the load. The extension structure is coupled to and extends between the base structure and the connector head structure. The extension structure includes a current constriction region configured to increase a magnetic flux density of a magnetic field produced by the current flowing through the current constriction region at a position of a magnetic current sensor that generates a sensor signal based on the magnetic field magnetic field produced by the current flowing through the current constriction region.