Planar Current Sensor Height Reduction via Magnetic Core
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Solution Overview
Problem
Current current sensors are not miniaturized enough due to the height of the magnetic core on the printed circuit board, which limits their compactness and integration in servo drive devices.
Innovation Solution
A current sensor design featuring a substrate with a through-hole and grooves, a primary conductor, and magnetic sensors positioned on the substrate to detect magnetic fields, with a magnetic body surrounding the conductor and partially located in the grooves to reduce height and enhance miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic core is arranged on the surface of the printed circuit board with a Hall element in the thickness direction, then the current detector can measure current accurately, but the height of the current detector becomes large
Solution Approach 1:
The invention transitions the magnetic core arrangement from the thickness direction (vertical dimension) to the plane direction (horizontal dimension) of the printed circuit board. The magnetic core is now arranged substantially in the plane of the board rather than standing upright, which reduces the height of the current detector while maintaining the measurement function through the magnetic flux path that goes through the plane of the board.
2Measurement precision
If a traditional magnetic core structure is used on the printed circuit board, then the Hall element can detect magnetic flux, but the current detector cannot be miniaturized
Solution Approach 1:
The magnetic core and Hall element arrangement is reconfigured from a vertical stack to a planar layout. The magnetic core lies substantially in the plane of the printed circuit board, and the Hall element is positioned to detect magnetic flux in this plane configuration, thereby reducing the volume of the current detector while preserving detection capability.
Solution Approach 2:
The invention integrates the magnetic core, Hall element, and circuit board into a more compact unified structure. The magnetic core is positioned adjacent to the Hall element in the plane of the board, and both are mounted on the same circuit board substrate, creating a merged assembly that reduces overall volume compared to traditional separate components.
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 allows for a significant reduction in height, enabling more compact current sensors that are less prone to external magnetic interference and easier to mount, while maintaining accurate current measurement.
Implementation Method 1
detects a strength of a magnetic field generated by a current to be measured flowing through the primary conductor
Data Source
AI summary
A current sensor includes a substrate including a through-hole and at least one groove around the through-hole, a primary conductor extending into the through-hole and through the substrate, and through which a current to be measured flows, at least one magnetic sensor that is mounted on a first surface of the substrate and detects a strength of a magnetic field generated by the current to be measured flowing through the primary conductor, and at least one magnetic body surrounding the primary conductor and including a portion extending in the at least one groove to be fixed to the substrate.