Slit Conductor Current Sensor for Functional Safety
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Solution Overview
Problem
Current sensor technologies for electric vehicles and conventional vehicles face challenges in achieving functional safety and compactness due to the bulkiness and high cost of combining diverse measurement principles like resistive-based and magnetic-based sensing.
Innovation Solution
A current sensor arrangement that includes a conductor with a slit dividing it into two portions, allowing for parallel current paths and a magnetic sensor positioned between them, enabling differential magnetic field sensing without the need for additional space or components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two diverse sensors (resistive-based and magnetic-based) are combined to improve functional safety rating, then measurement reliability is improved, but device size and cost increase
Solution Approach 1:
The patent combines resistive-based and magnetic-based sensing principles into a single integrated current sensor device. The conductor with slit structure serves both as the measurement element for resistive sensing and as the source of magnetic field for magnetic sensing, eliminating the need for separate sensor components and reducing overall device size while maintaining dual measurement capabilities for improved functional safety
Solution Approach 2:
The conductor with slit configuration performs multiple functions simultaneously: it conducts the primary current, generates the magnetic field, and provides the structural framework for both resistive and magnetic measurement. This multi-functional design allows a single component to replace what would traditionally require multiple separate components, reducing device volume while maintaining reliability
2Reliability
If two diverse sensors (resistive-based and magnetic-based) are combined to improve functional safety rating, then measurement reliability is improved, but device cost increases
Solution Approach 1:
The patent merges resistive and magnetic sensing into a single device architecture, reducing the total component count and assembly complexity. By using the same conductor structure for both measurement principles, the patent eliminates the need for separate sensor housings, mounting structures, and interconnections, thereby reducing manufacturing costs despite the enhanced functional safety capabilities
3Measurement precision
If a slit is formed in the conductor to create parallel current paths for magnetic field generation, then magnetic sensing capability is improved, but conductor structural integrity may be compromised
Solution Approach 1:
The patent divides the conductor into multiple parallel current paths by forming a slit that extends partially through the conductor thickness. This segmentation creates distinct current paths that generate controllable magnetic fields while the slit depth is carefully controlled to maintain sufficient structural integrity. The conductor is divided into first and second conductor portions that remain mechanically connected while providing separate current paths for precise magnetic field generation
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 solution enhances functional safety by robustly detecting faults and reducing size and cost, while maintaining efficient current measurement through the combination of resistive and magnetic sensing principles.
Implementation Method 1
a first current that produces a first magnetic field as it flows through the first conductor portion in the current flow direction and a second current that produces a second magnetic field as it flows through the second conductor portion
Data Source
AI summary
A current sensor arrangement includes a first conductor configured to conduct a first portion of a primary current in a current flow direction; a second conductor configured to conduct a second portion of the primary current in the current flow direction; and a magnetic sensor. The first and second conductor are coupled in parallel. The first current produces a first magnetic field as it flows through the first conductor and the second current produces a second magnetic field as it flows through the second conductor. The first conductor and the second conductor are separated from each other in a first direction that is orthogonal to the current flow direction, thereby defining a gap. The magnetic sensor is arranged in the gap such that the first conductor is arranged over a first portion of the magnetic sensor and the second conductor is arranged under a second portion of the magnetic sensor.