Current Measuring Device Using Soft-Magnetic Core in Frame
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Solution Overview
Problem
Power electronic systems require current measurement, but existing solutions, such as plug connections with Hall sensors, occupy excessive installation space and incur high costs, particularly in automobile applications.
Innovation Solution
A current measuring device with a soft-magnetic core surrounding the electrical conductor and a magnetically sensitive sensor, such as a Hall sensor, integrated within a glass fiber reinforced plastic frame, eliminating the need for external connections and allowing for compact packaging and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a plug connection with Hall sensor is used for current measurement, then current detection is achieved, but installation space increases and costs increase
Solution Approach 1:
The patent combines the current measuring device with the frame structure by integrating the soft-magnetic core and Hall sensor directly into the frame. This merging eliminates the need for separate plug connections and external current measuring devices, thereby reducing installation space while maintaining current detection functionality.
Solution Approach 2:
The frame structure is given multiple functions: it serves as both the structural support and as the housing for the current measuring device. The soft-magnetic core integrated into the frame serves dual purposes of providing magnetic shielding and concentrating magnetic flux for the Hall sensor. This multi-functionality eliminates the need for additional plug connections and reduces overall installation space.
2Measurement precision
If a plug connection with Hall sensor is used for current measurement, then current detection is achieved, but costs increase
Solution Approach 1:
The patent merges the current measuring device with the frame structure, eliminating the need for separate plug connections and external housing. This integration reduces the number of components that need to be manufactured and assembled, thereby reducing manufacturing costs while maintaining current detection capability.
Solution Approach 2:
The frame structure performs multiple functions including structural support, magnetic flux concentration, and housing for the Hall sensor. This multi-functionality reduces the total component count and assembly complexity, leading to lower manufacturing costs compared to using separate plug connections with Hall sensors.
3Measurement precision
If the current measuring device is arranged externally with plug connections, then current detection is achieved, but assembly complexity increases and reliability decreases
Solution Approach 1:
The patent integrates the current measuring device directly into the frame structure, combining multiple functions into a single unified component. This eliminates the need for separate plug connections and external wiring, significantly simplifying assembly while maintaining current detection accuracy.
4Measurement precision
If the current measuring device is arranged externally with plug connections, then current detection is achieved, but reliability decreases
Solution Approach 1:
The patent merges the current measuring device with the frame structure, eliminating external plug connections and wiring. This integration reduces the number of potential failure points from connectors and external wiring, thereby improving reliability while maintaining current detection functionality.
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 configuration minimizes installation space, reduces costs, enhances packing density, simplifies assembly, and improves reliability by eliminating external connections and providing effective thermal coupling for the current measuring device.
Implementation Method 1
the magnetic field lines that form when current flows along an electrical conductor are concentrated by an approximately ring-shaped, soft-magnetic core
Implementation Method 2
A magnetically sensitive sensor, preferably a Hall sensor, is arranged in this recess. The electrical voltage induced in a Hall sensor is proportional to the strength of the magnetic field induced by the current flowing in the conductor
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a current measuring device in a power electronics system, which comprises at least one circuit board (9) and an electric conductor (4) which is guided through a frame (1) that surrounds the circuit board. According to the main idea of the invention, the current measuring device encompasses a soft-magnetic core (3) surrounding the insulation of the electric conductor (4), said core being disposed in the frame (1). The soft-magnetic core (3) is open at one location (6). A magnetically sensitive sensor (5), in particular a Hall sensor, is arranged in the recess (6) of the soft-magnetic core (3) that surrounds the insulation of the electric conductor (4) in order to detect the magnetic field strength.