Compact Current Sensor with Offset Conductor for Inverter Space Saving
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Solution Overview
Problem
Existing electrical current sensors for measuring output currents of inverters in electric vehicles are bulky due to screwing constraints, which occupy significant space and hinder the compact placement of inverters near electric motors.
Innovation Solution
A compact sensor design featuring a magnetic C with a main opening close to one portion of an electrical conductor and offset with respect to another portion, allowing for reduced bulk and space savings by eliminating screwing zones on the output connectors of the inverter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screwing zones are provided on output connectors of the inverter, then reliable electrical connection is achieved, but significant space is occupied and inverter placement near electric motor is hindered
Solution Approach 1:
The patent extracts the screwing zone from the output connector of the inverter by introducing an intermediate electrical conductor. This conductor has a first portion that receives the inverter connector and a second portion offset from the magnetic C, providing a separate screwing zone. This removes the space occupation problem from the original connector while maintaining reliable electrical connection through the intermediate conductor.
Solution Approach 2:
The patent introduces an intermediate electrical conductor as a mediator between the inverter output connector and the electric motor phase connector. This intermediate conductor with offset portions allows both reliable electrical connection and compact space utilization, solving the contradiction between connection reliability and space occupation.
2Measurement precision
If magnetic C is positioned close to electrical connector for current measurement, then measurement accuracy is improved, but space for connector assembly is reduced
Solution Approach 1:
The patent segments the electrical connection path into distinct portions: the first portion of the electrical conductor receives the inverter connector with the magnetic C positioned close for accurate measurement, while the second portion is offset to provide assembly space. This segmentation allows both measurement precision and assembly space requirements to be satisfied simultaneously.
Solution Approach 2:
The patent resolves the space conflict by utilizing spatial offset in another dimension. The electrical conductor is configured with portions offset from each other, allowing the magnetic C to be positioned close to one portion for measurement while providing space near another portion for connector assembly, effectively using dimensional arrangement to satisfy both requirements.
3Volume of moving object
If inverter is placed close to electric motor, then space efficiency is improved, but screwing constraints prevent compact placement
Solution Approach 1:
The patent extracts the screwing constraint from the inverter connector by providing the screwing zone on the offset second portion of the intermediate electrical conductor. This allows the inverter to be placed close to the electric motor for space efficiency while the screwing operation can be performed on the intermediate conductor without spatial constraints.
Solution Approach 2:
The intermediate electrical conductor serves as a mediator that decouples the screwing constraint from the inverter-motor placement. By providing a dedicated screwing zone on the offset portion, it enables compact inverter-motor placement while maintaining ease of manufacture through accessible screwing operations on the intermediate conductor.
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 sensor effectively measures output currents with reduced size, achieving a space saving of approximately 15 mm between the inverter and electric motor, addressing the constraint of compactness and space efficiency.
Implementation Method 1
a magnetic C arranged so as to pick up the magnetic field induced by the output current of the first electrical system
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a sensor (1) for measuring the output current of a first electrical system connected to a second electrical system, said sensor (1) comprising at least one magnetic C (31, 32, 33) extending in a principal plane in which it has a C-shape, said magnetic C (31, 32, 33) having a principal opening (O) delimited in the principal plane by said C-shape, said sensor (1) comprising at least one electrical conductor having at least a first portion (51, 52, 53) configured to receive an electrical connector of the first electrical system and at least a second portion (61, 62, 63) configured to receive an electrical connector of the second electrical system so as to ensure an electrical connection between the first and second electrical systems, said first portion (51, 52, 53) being located opposite the principal opening (O) of the magnetic C (31, 32, 33) and the second portion (61, 62,63) being offset relative to the magnetic C (31, 32, 33) along the principal plane.