High Current Measuring Device Using Segmented Metal Bar
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Solution Overview
Problem
Conventional high current measuring devices face challenges in measuring high currents efficiently due to size constraints and precision issues, particularly when using shunt resistors, core and winding methods, and Hall effect sensors, which often require larger sizes and complex configurations.
Innovation Solution
A high current measuring device that utilizes a metal bar with a branch set and a current sensor module, where the current is divided among branches, allowing the current sensor to measure partial current from the center branch, with bottleneck parts ensuring a consistent current ratio and precision, and a calibration unit to calculate the entire current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a core and winding method is used to measure high current, then the measurement can be performed, but the size of the core and the number of windings must be increased to surround a conductor with large cross-section
Solution Approach 1:
The conductor is divided into multiple branches (first branch, second branch, third branch, fourth branch) instead of requiring a single large core to surround the entire conductor. Each branch is measured separately by individual current sensors, and the results are combined to obtain the total current. This segmentation allows using smaller cores for each branch rather than one large core for the entire conductor.
Solution Approach 2:
Instead of measuring the entire current directly through a large core surrounding the whole conductor, the invention measures partial currents from individual branches separately and combines them. This partial measurement approach allows using smaller sensing components for each branch while achieving accurate total current measurement through summation.
2Adaptability or versatility
If a Hall effect sensor is inserted into a large gap to measure high current, then AC/DC can be measured simultaneously, but the size of the core must be increased proportionally, posing challenges in securing precision
Solution Approach 1:
The measurement system is segmented into multiple independent branch measurements rather than using a single large core with Hall effect sensor. Each branch has its own current sensor that can handle AC/DC independently, and the results are combined. This avoids the need for a large gap while maintaining AC/DC measurement capability and improving precision through multiple smaller measurements.
3Measurement precision
If shunt resistance is used to measure high current, then the voltage at the resistor can be measured, but loss and insulation problems occur
Solution Approach 1:
The invention replaces the shunt resistance method (which causes I²R losses) with a magnetic field-based measurement approach using current sensors and cores. This substitution eliminates the direct resistive loss mechanism while maintaining current measurement capability through electromagnetic induction and field sensing.
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
Enables precise measurement of high currents in a smaller size without sensing the entire current, maintaining high precision and accuracy regardless of connecting point locations, and applicable for both AC and DC currents.
Implementation Method 1
a current sensor module 20 coupled thereto, wherein a plurality of branches, through which the entire current is divided and flows, is disposed adjacent to each other, and the current sensor module 20 is mounted on a center branch 11c in a center among the plurality of branches included in the branch set 11
Data Source
AI summary
Proposed is a high current measuring device for measuring an entire current flowing through a metal bar (10), wherein the metal bar (10) is a rectangle, has a plate-shaped outline, and includes an even number of split slits (11a, 11b) disposed in a widthwise direction at a center of a longitudinal direction so that a branch set 11, which includes branches (in an odd number no smaller than 3) through which the entire current is divided and flows, is provided, a 1-1 notch (12a) and a 1-2 notch (12b) respectively provided by being concaved inward from two longer sides of the rectangle at the front ends of the split slits (11a, 11b), and a 2-1 notch (14a) and a 2-2 notch (14b) respectively provided by being concaved inward from two longer sides of the rectangle at the rear ends of the split slits (11a, 11b).