Magnetic Field Sensor Chip Mounting on Busbar via Segmented Adapter

Solution Overview

Problem

Existing current measurement systems for busbars using magnetic field sensors require complex and costly adaptations to different busbar geometries and installation situations, leading to increased manufacturing complexity and expense.

Innovation Solution

A current measuring system comprising a magnetic field sensor chip in a busbar-nonspecific sensor housing, secured by an adapter piece tailored to the busbar geometry, allowing for standardized and cost-effective manufacturing, with the adapter piece being fixable to the busbar using various mechanisms such as plugs, clips, or threads to maintain the sensor in a predetermined measurement position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If magnetic field sensor concepts are tailored to different busbars and installation situations, then measurement robustness is improved, but manufacturing complexity and costs increase

Engineering Contradiction:

Improvemeasurement robustnessVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system is divided into two independent parts: a universal sensor device with standardized geometry and a busbar-specific adapter piece. The adapter piece is segmented to match the specific busbar geometry while the sensor remains standardized, allowing tailored adaptation without customizing the entire sensor system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An adapter piece serves as an intermediary component between the standardized sensor device and the busbar with specific geometry. The adapter translates the universal sensor interface to the specific busbar requirements, enabling measurement robustness for different busbars without modifying the sensor itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If magnetic field sensor concepts are tailored to different busbars and installation situations, then measurement robustness is improved, but manufacturing costs increase

Engineering Contradiction:

Improvemeasurement robustnessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system is divided into two independent parts: a universal sensor device with standardized geometry and a busbar-specific adapter piece. The adapter piece is segmented to match the specific busbar geometry while the sensor remains standardized, allowing tailored adaptation without customizing the entire sensor system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor device is designed with universal geometry and mounting interfaces that can work with any busbar type through the appropriate adapter piece. This universality allows the same sensor design to be mass-produced and reused across different applications, reducing per-unit costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If the sensor housing geometry is adapted to the busbar geometry, then installation precision is improved, but manufacturing flexibility decreases

Engineering Contradiction:

Improveinstallation precisionVSAvoidmanufacturing flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system is divided into two independent parts: a universal sensor device with standardized geometry and a busbar-specific adapter piece. The adapter piece is segmented to match the specific busbar geometry while the sensor remains standardized, allowing tailored adaptation without customizing the entire sensor system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An adapter piece serves as an intermediary component between the standardized sensor device and the busbar with specific geometry. The adapter translates the universal sensor interface to the specific busbar requirements, enabling measurement robustness for different busbars without modifying the sensor itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach reduces manufacturing complexity and costs by allowing the same sensor system to be adapted to various busbar geometries through a cost-effective adapter piece, ensuring accurate and reliable current measurement without the need for individual customization of the sensor chip or housing.

Implementation Method 1

measuring an electric current through a busbar by means of magnetic field sensors

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Data Source

PatentUS11366139B2Device and method for mounting a magnetic field sensor chip on a busbar

Publication Date: 2022.06.21 INFINEON TECHNOLOGIES AG

AI summary

The present disclosure relates to a current measuring system. The current measuring system includes a busbar, a magnetic field sensor chip encased by a sensor housing, wherein a geometry of the sensor housing is independent of a geometry of the busbar; and an adapter piece for receiving the sensor housing, said adapter piece being adapted to the geometry of the busbar, wherein the adapter piece is fixable to the busbar, wherein the magnetic field sensor chip is fixed in a predetermined measurement position when the sensor housing is received into the fixed adapter piece.