Inverter Current Sensor Housing for Thin Magnetic Shielding
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Solution Overview
Problem
Existing power conversion devices face challenges in achieving both reduction in thickness and suppression of magnetic interference, which are necessary to meet customer requirements.
Innovation Solution
A power conversion device is designed with an inverter circuit, AC conductor, magnetic sensor, and magnetic bodies arranged to minimize magnetic interference by using conductive housings to cover openings between magnetic bodies, ensuring the ends of these bodies are closer to the housings than their thickness, and incorporating magnetic flux guiding structures to suppress leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If magnetic bodies are extended further to suppress magnetic flux leakage, then magnetic interference suppression is improved, but device thickness increases
Solution Approach 1:
The patent transitions from extending magnetic bodies in the thickness direction to covering openings with housings in the lateral direction. This dimensional shift allows magnetic flux containment without increasing device thickness, resolving the contradiction between magnetic interference suppression and compact form factor.
Solution Approach 2:
The patent divides the magnetic flux containment function into two parts: magnetic bodies for guiding flux and housings for covering openings. This segmentation allows each component to perform its function efficiently without requiring excessive thickness, as the housings provide the containment barrier at the openings rather than relying solely on extended magnetic bodies.
2Length of stationary object
If magnetic bodies are made thinner to reduce device thickness, then device compactness is improved, but magnetic flux leakage increases
Solution Approach 1:
The housing acts as an intermediary structure that complements the thinned magnetic bodies. While the magnetic bodies are made thinner to reduce device thickness, the housing covers the openings to prevent magnetic flux leakage, allowing the system to achieve both compactness and effective flux containment.
3Ease of manufacture
If housings are positioned farther from magnetic bodies to facilitate assembly, then ease of manufacture is improved, but magnetic shielding effectiveness decreases
Solution Approach 1:
The patent optimizes the distance parameter between housings and magnetic bodies to achieve an optimal balance. The housings are positioned close enough to effectively contain magnetic flux but far enough to allow practical assembly operations, transforming the assembly difficulty into a manageable parameter through careful design specification.
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 design achieves both reduction in thickness and improved magnetic interference suppression, enhancing current detection accuracy and assemblability while maintaining detection sensitivity.
Implementation Method 1
a magnetic sensor that detects magnetism generated when the AC current flows through the AC conductor
Implementation Method 2
a magnetic sensor that detects magnetism generated when the AC current flows through the AC conductor
Implementation Method 3
a first magnetic body and a second magnetic body that face each other with the AC conductor and the magnetic sensor interposed therebetween
Implementation Method 4
a first housing and a second housing that are formed by conductive members. The first housing covers one opening of a space located between the first magnetic body and the second magnetic body
Data Source
AI summary
A power conversion device includes: an inverter circuit; an AC conductor; a magnetic sensor that t detects magnetism generated when an AC current flows; a first magnetic body and a second magnetic body that face each other with the AC conductor and the magnetic sensor interposed therebetween; and a first housing and a second housing that are formed by conductive members. The first housing covers one opening of a space located between the first magnetic body and the second magnetic body, the second housing covers the other opening of the space. The end of each of the first magnetic body and the second magnetic body is formed so that the distance to the first housing or the second housing is smaller than the thickness of each of the first magnetic body and the second magnetic body in the arraying direction thereof.