Power Connector Current Sensing With Torque-Stable Mounting
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Solution Overview
Problem
Core-based magnetic current sensors face issues such as high cost, complex assembly, inefficiencies, inaccuracies, and size, while coreless sensors struggle with reduced flux density and difficulty in routing current without increasing device size, lacking a universal differential sensing solution.
Innovation Solution
A power connector design with a conductive frame and magnetic current sensor that includes a current constriction region to enhance magnetic flux density, integrated with a torque stabilization mechanism to prevent torque transfer, enabling accurate current measurement without a field concentrator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a core-based magnetic sensor is used, then measurement precision is improved through flux density amplification, but device complexity and manufacturing cost increase due to the field concentrator assembly
Solution Approach 1:
The patent removes the ferrous field concentrator from the sensor assembly, transitioning from a core-based to a coreless magnetic current sensor. This extraction eliminates the complex assembly of routing current rails through field concentrators while maintaining measurement capability through direct flux density sensing at the conductor surface.
Solution Approach 2:
The patent replaces expensive, complex ferrous field concentrators with a simpler coreless sensor design that uses minimal structural material. The connector body itself serves as the mounting structure, eliminating the need for separate field concentrator components and reducing overall manufacturing cost.
2Device complexity
If a coreless current sensor is used, then device complexity is reduced, but measurement precision deteriorates due to significantly reduced flux density at sensitive elements
Solution Approach 1:
The patent concentrates the magnetic flux density at a specific location by positioning the sensor elements directly at the conductor surface where flux density is naturally highest. The connector head structure creates a localized sensing zone with enhanced flux concentration, allowing coreless sensors to achieve sufficient measurement precision without requiring field concentrators.
Solution Approach 2:
The patent transitions from measuring flux density at a distance (through a field concentrator) to measuring directly at the conductor surface (zero-dimensional contact). This dimensional change places the sensor elements in the most intense part of the magnetic field, compensating for the lack of flux amplification in coreless designs.
3Reliability
If differential sensing is implemented, then reliability is improved through EMI immunity, but device complexity increases due to routing difficulties and size requirements
Solution Approach 1:
The patent combines the differential sensing elements into a single integrated sensor unit that is mounted directly on the connector body. This merging eliminates the need for separate routing of test current through differential sensing structures, reducing device complexity while maintaining EMI immunity through the inherent differential measurement capability.
4Strength
If torque is applied during fastening without stabilization, then mechanical strength is improved, but measurement precision deteriorates due to torque transfer to the sensor area
Solution Approach 1:
The patent introduces a torque stabilization tool as an intermediary between the fastening operation and the sensor area. This tool prevents torque from being transferred to the connector head and sensor during fastening, protecting measurement precision while allowing full mechanical strength to be achieved through proper fastening.
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 provides accurate current measurement with enhanced flux density and mechanical stability, reducing manufacturing costs and complexity by integrating a differential magnetic sensor within a power connector.
Implementation Method 1
the current constriction region is configured to increase a magnetic flux density of a magnetic field produced by the current flowing through the current constriction region
Implementation Method 2
a magnetic current sensor arranged proximate to a sensor area of the extension structure to receive the magnetic field having the increased magnetic flux density produced by the current flowing through the current constriction region
Data Source
AI summary
A power connector is provided that is configured to conduct a current. The power connector includes a base structure, an extension structure, and a connector head structure that define a current path for the current. The extension structure is coupled to and extends between the base structure and the connector head structure. The connector head structure includes a bore-hole that vertically extends into the connector head structure toward the base structure. The bore-hole is configured to receive a fastener for coupling the power connector to an electrical interface of a device. The connector head structure has a mechanical engagement feature configured to mechanically engage with a torque stabilization tool during a fastening of the fastener to the connector head structure in order to prevent a torque applied by the fastening of the fastener from being transferred to the extension structure.