Power Module Hall Sensing Layout for Compact Current Detection
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Solution Overview
Problem
Existing power modules in eco-friendly vehicles require external current sensors or internal resistors for current detection, which increase volume and cost, and are prone to inaccuracies due to temperature and magnetic field interference.
Innovation Solution
Integrate a Hall element between substrates within the power module to sense current, generating voltage from magnetic fields, reducing the need for external sensors and resistors, and minimizing interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external current sensors or internal resistors are used for current detection, then current sensing can be performed, but the volume and cost of the power module increase
Solution Approach 1:
The Hall element is integrated directly between the first and second substrates within the power module, merging the current sensing function with the power module structure itself. This eliminates the need for separate external current sensors and reduces overall volume while maintaining sensing capability.
Solution Approach 2:
The Hall element is nested within the power module structure, specifically positioned between the first substrate (carrying current) and the second substrate. This nested arrangement allows the sensing function to be embedded within the existing power module footprint without requiring additional external space.
2Measurement precision
If external current sensors or internal resistors are used for current detection, then current sensing can be performed, but the cost of the power module increases
Solution Approach 1:
By combining the current sensing function into the power module structure itself through the Hall element, the need for separate external sensing components is eliminated. This integration reduces the total bill of materials and assembly complexity, thereby lowering manufacturing cost.
Solution Approach 2:
The sensing function is extracted from external components and incorporated directly into the power module's internal structure. This extraction eliminates the need for separate purchased components and reduces assembly steps, leading to cost reduction.
3Measurement precision
If external current sensors or internal resistors are used for current detection, then current sensing can be performed, but accuracy is reduced due to temperature and magnetic field interference
Solution Approach 1:
The Hall element acts as an intermediary that senses current through magnetic field detection rather than direct electrical contact. This indirect sensing mechanism isolates the sensing function from temperature effects and electrical interference that would directly affect resistor-based sensing, improving accuracy.
4Volume of stationary object
If a Hall element is integrated between substrates within the power module, then size and cost are reduced, but the complexity of integration increases
Solution Approach 1:
The Hall element is positioned in the vertical dimension between the first and second substrates, utilizing the z-axis space rather than requiring additional lateral space. This dimensional approach to integration simplifies the layout and reduces planar complexity while achieving compact integration.
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 the size and cost of the current sensor and power module, enhances sensing accuracy, and provides a more spacious internal layout for the inverter.
Implementation Method 1
a Hall element disposed between the first substrate and the second substrate to face the sensing target portion with an interval with the sensing target portion, and electrically connected to the outside of the power module, and configured to generate voltage according to a magnetic field occurring due to a current flowing in the sensing target portion
Data Source
AI summary
A power module includes a first substrate including a sensing target portion in which a current path is formed in a first direction, a second substrate spaced from the first substrate in a second direction crossing the first substrate, and a Hall element disposed between the first substrate and the second substrate to face the sensing target portion with an interval with the sensing target portion, and electrically connected to the outside of the power module, and configured to generate voltage according to a magnetic field occurring due to a current flowing in the sensing target portion.