Thin-Walled Magnetic Core for Compact Hall Effect Current Sensors
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Solution Overview
Problem
Conventional Hall effect current sensors are bulky, limiting the size reduction of photovoltaic string monitors due to their large magnetic core dimensions, which affects the center-to-center spacing of conductors and overall system size, and are costly to manufacture with existing techniques.
Innovation Solution
The development of thin-walled magnetic core elements with a thickness ratio of inner diameter to thickness greater than 10:1, fabricated from single sheets of magnetic material like 80% nickel molybdenum alloy, allowing for compact Hall effect current sensor designs with reduced dimensions while maintaining performance, and using these cores in combination with Hall sensor elements and printed circuit boards within a housing to form compact, efficient current sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional magnetic core elements are used in Hall effect current sensors, then reliable current measurement is achieved, but the sensor size becomes large and bulky
Solution Approach 1:
The patent applies this principle by using thin-walled magnetic core elements with wall thicknesses of 0.5mm to 2.0mm, replacing conventional thick-walled cores. The thin-walled structure maintains magnetic functionality while significantly reducing sensor volume, enabling compact Hall effect current sensor designs without compromising measurement reliability
Solution Approach 2:
The patent changes the geometric parameters of the magnetic core by establishing specific thickness ratios (inner diameter to thickness greater than 10:1) and using optimized wall thicknesses. These parameter changes allow the magnetic core to maintain sufficient magnetic flux concentration for reliable measurement while achieving compact sensor dimensions
2Volume of moving object
If thin-walled magnetic core elements are used to reduce sensor size, then compact design is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the magnetic core into thin-walled cylindrical structures with standardized thicknesses (0.5mm, 1.0mm, 1.5mm, 2.0mm). This segmentation approach allows for modular manufacturing processes and simplifies production by using discrete thickness specifications rather than custom-shaped cores
Solution Approach 2:
The patent employs composite construction by combining thin-walled magnetic core elements with Hall sensor elements and printed circuit boards within a housing. This composite approach allows each component to be manufactured separately using optimized processes, then assembled into a compact integrated sensor unit
3Length of moving object
If thin-walled magnetic core elements are used, then center-to-center spacing of conductors is reduced, but manufacturing cost increases
Solution Approach 1:
The patent establishes standardized thickness parameters (0.5mm to 2.0mm) and thickness ratios (inner diameter to thickness > 10:1) that optimize the balance between compactness and manufacturability. These parameter specifications enable cost-effective production through standardized manufacturing processes while achieving reduced center-to-center spacing
Solution Approach 2:
The thin-walled magnetic core design serves multiple functions: it provides magnetic flux concentration, enables compact sensor dimensions, and allows for standardized mass production. This multi-functionality reduces overall system complexity and manufacturing costs despite the reduced dimensions
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 enables a significant reduction in the size of Hall effect current sensors, allowing for more efficient use of space in photovoltaic power systems by minimizing the center-to-center spacing of conductors, while maintaining reliable current measurement capabilities and simplifying manufacturing processes.
Implementation Method 1
Hall effect sensors typically include a housing, a magnetic core element including a gap, and a Hall element in the gap. When subjected to a magnetic field associated with the current flow in the conductor, the Hall element responds with an output voltage proportional to the magnetic field strength.
Implementation Method 2
When electrical current flows through the conductor, a magnetic field is generated that varies with the amount of current flow. The magnetic field is concentrated in the gap of the core element and measured by the Hall element.
Data Source
AI summary
A non-contact magnetic sensor assembly includes a thin-walled magnetic ring that facilitates a reduction in the size of the device without compromising performance. The component assembly may be configured as a Hall effect current sensor and may be included in a string monitor for a photovoltaic power system.