Shielded Bus Bar Current Sensor Assembly for Linear 3-Phase Sensing
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Solution Overview
Problem
Existing current sensors in electric vehicles are prone to errors due to separate configurations of bus bars, current sensors, and shields, which can cause structural challenges and inaccuracies in current measurement, and are difficult to optimize relative positions and distances.
Innovation Solution
A current sensor assembly where the bus bar, current sensor, and shield are integrated as a single configuration within a housing, with optimized positions and distances to ensure linear current measurement, reduced vibration, and minimized crosstalk and phase delay effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar, current sensor, and shield are provided as separate configurations, then the current sensor can be independently replaced or adjusted, but measurement errors occur and structural changes are difficult
Solution Approach 1:
The bus bar, current sensor, and shield are merged into a single integrated assembly where the current sensor is mounted directly on the bus bar with the shield positioned adjacent to both components. This integration eliminates measurement errors caused by separate configurations while maintaining replaceability of individual components through modular design
2Measurement precision
If the bus bar, current sensor, and shield are combined as one configuration, then measurement accuracy improves, but the structure becomes more complex to manufacture
Solution Approach 1:
The integrated assembly is segmented into distinct modules (bus bar, current sensor, shield) that can be manufactured separately and then assembled together. This allows each component to be optimized for manufacturing while achieving the benefits of integration for measurement precision
3Measurement precision
If the current sensor is positioned close to the bus bar, then measurement sensitivity increases, but crosstalk and phase delay effects increase
Solution Approach 1:
The shield acts as an intermediary component positioned between the bus bar and the current sensor, and also between adjacent bus bars. This shielded configuration reduces crosstalk and phase delay effects while allowing the current sensor to remain positioned close to the bus bar for high measurement sensitivity
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
Accurate current detection is achieved with reduced errors from vibration and improved linearity, while optimizing the sensor's position relative to the bus bar and shield to minimize crosstalk and phase delay.
Implementation Method 1
a current sensor unit comprising a printed circuit board and a plurality of current sensors disposed on the printed circuit board to measure the current applied to the plurality of bus bars
Implementation Method 2
a plurality of shields which are accommodated inside the housing and open toward a top of the housing
Data Source
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AI summary
The present invention relates to a current sensor assembly comprising: a housing; a plurality of shields which are accommodated inside the housing and open toward the top of the housing; a plurality of bus bars to which three-phase current is applied and which are arranged spaced apart from each other so as to go past the plurality of shields, respectively; and a current sensor unit which includes a printed circuit board and a plurality of current sensors disposed on the printed circuit board to measure the current applied to the bus bars, wherein the shields, the bus bars, and the current sensor unit are configured to be accommodated inside the housing, and the current sensors are spaced apart from the bus bars and disposed in the inner spaces of the shields.