PCB Current Sensor Assembly for Scaled High-Current Measurement
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Solution Overview
Problem
Current sensors have a defined measuring capacity, leading to increased cost and space occupation as higher capacity sensors are required for measuring higher currents, which also increases production costs and PCB space usage.
Innovation Solution
A current sensor assembly that includes a lower-rated capacity sensor and conductive tracks or busbars on a PCB to measure higher currents by scaling measurements with a processing unit, allowing current values beyond the sensor's capacity to be accurately determined.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a higher capacity current sensor is used to measure higher currents, then the measuring capacity is improved, but the cost and PCB space occupation increase
Solution Approach 1:
The patent divides the current measurement function into two parts: a lower-capacity sensor that measures a portion of the current, and a processing unit that calculates the total current by combining the sensor measurement with a scaling factor. This segmentation allows using a smaller sensor while still achieving higher current measurement capability.
Solution Approach 2:
The patent changes the measurement parameter by using a scaling factor to convert the sensor's output (measuring a portion of current) into the total current value. This parameter transformation allows the system to measure higher currents than the sensor's direct capacity while using a lower-capacity component.
2Measurement precision
If a higher capacity current sensor is used to measure higher currents, then the measuring capacity is improved, but the production cost increases
Solution Approach 1:
The patent segments the measurement system into a low-cost, lower-capacity sensor and a processing unit that performs mathematical calculations. This division allows the use of cheaper sensor components while achieving the required measurement capability through software-based scaling, thereby reducing overall production cost.
Solution Approach 2:
The patent creates a scaled representation of the actual current by using a scaling factor. Instead of directly measuring the full current with an expensive high-capacity sensor, the system measures a scaled-down version of the current and mathematically reconstructs the full value, effectively using a cheaper component to achieve the same measurement goal.
3Measurement precision
If a higher capacity current sensor is used to measure higher currents, then the measuring capacity is improved, but the sensor dimensions increase
Solution Approach 1:
The patent segments the current measurement task so that a smaller sensor only needs to handle a portion of the total current. The sensor's physical dimensions remain small because it only needs to measure a fraction of the total current, while the processing unit handles the mathematical scaling to determine the full current value.
Data Source
AI summary
A current sensor assembly includes at least a portion of a printed circuit board; at least one sensor disposed on the portion of the printed circuit board, the at least one sensor being configured to measure current flowing through the portion of the printed circuit board; and a processing unit configured to: receive one or more current measurements from the at least one sensor; and determine an actual current value associated with the current flowing through the portion of the printed circuit board by scaling the one or more current measurements.