A Novel Contact-less Current Sensor for HEV/EV and Renewable … · Tria⊗⊗s⊗i => IMC...

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Small things make a big difference.

Melexis “Hall”

Presentation

A Novel Contact-less

Current Sensor

for HEV/EV and Renewable Energy

Applications

ROR-MLX

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“Contact-less” Current Sensing

Conventional Hall Tria⊗⊗⊗⊗is Hall

Conventional Hall

Element

ICurrent Conductor

Vout

l0

• CMOS HALL IC with IMC, Packaged in SO-8• Measures the field generated by the current

Tria⊗⊗⊗⊗is => IMC integrated magnetic concentrator

Melexis markets a patented Hall technology under the brand ‘Triaxis™’. This technology enables the realization of cutting-edge contactless magnetic position sensors. Triaxis™ ICs are designed in rotary, linear and 3D-joystick position sensor.

• Open Loop Current Sensor

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Conventional Current Sensors

Open Loop Current Sensor

Features

- AC/DC; BW < 10- 50 kHz

- Accuracy <3-5% error

- Material non linearity

- Temperature drift

Conventional Hall Plate

Soft Ferromagnetic Core

ICurrent Conductor

Vout

Air gap: B ≈ I * µ0 / l0

Vout = S * B

Open Loop Current Sensor: Non-linearity

due to B-H-curve of core material

-2

-1

0

1

2

-200 -100 0 100 200

current [A]

ou

tpu

t sig

na

l [V

]

l0

Accuracy is limited by the ferromagnetic core i.e. hysteresis !

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IMC Current Sensor

Current Sensor MLX91205

Differential outputDifferential outputDifferential outputDifferential output

----3333----2222----11110000111122223333

----10101010 ----7.57.57.57.5 ----5555 ----2.52.52.52.5 0000 2.52.52.52.5 5555 7.57.57.57.5 10101010

Magnetic field Magnetic field Magnetic field Magnetic field mTmTmTmT

V ou

t diff

V ou

t diff

V ou

t diff

V ou

t diff

ampsIr

B **2

0

π

µ≈

Contact-less, low-cost, open-loop, SO-8

I

B

CSENTRONSA-1V

V

V ~ I

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IMC Current Sensor

MLX91205

IMC = Integrated Magnetic Concentrator

Photograph of ASIC withattached twin IMC

The IMC transforms a lateral fieldlocally into a vertical field

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IMC Current Sensor

Then the flux lines go in here

And they come outhere

Part of the flux lines pass through the chip underneath the gap

We structure Integrated Magnetic Concentrators (IMC) made of soft ferromagnetic material on the chip surface !

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IMC Current Sensor

Benefits of the IMC Technology

sensitive parallel with chip surface

► easier mounting of sensor for many applications

► new opportunities for combining sensor and current lead

locally increased flux density (magnetic gain)

► higher output signal

► lower field equivalent offset

► lower field equivalent noise

IMC boosts the the performance of CMOS-Hall-Sensors

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IMC Current Sensors

� contact less -> voltage isolation from conductor to any level and good thermal isolation.

� small dimension SO-8, standard assembling technique on pcb

� high bandwidth 100kHz, very fast response time!

� high modularity (adapt sensor to conductor – i.e. shield)

� IMC give magnetic gain -> higher S/N; very low Br – Hc

� small, robust and economical solution…

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Market /Application

� Battery Current BMS, Battery Charger (HEV)

� Inverter for HEV (traction motor control)

� Renewable Energy (Wind/Solar Power Converter) (Power Extractor, Battery Charger and Inverters)

� Power Supply for Telecommunication, Server,..

Current sensors

Requirements: current range = 10 – 1000 Amps

Response time < 10 usec.,

Small, robust and economical

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Current Sensor Automotive

HEV and EVDC-DC Power Converter

300V -> 14V, 120A

“Bus-Bar” Current Sensor for Battery Monitoring or Inverter Application

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Solar Power Converter

� Data Monitoring for renewable energy

� DC-DC and DC-AC converters in the range of 200W - 2KW

� Solar power extractor charge controller

DC-AC conver

ter

Current

measurement

Current measurement

DC-DC

Converter

DC-AC

Inverter

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Application: direct on PCB

Sensitivity: 40mV/Amp, Range: ± 50 Amp, Resolution: 0.08Amp (@10khz)

Example: IMC Current Sensor (20/50A)

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Application: Bus Bar +/-200A

� Demonstrator for Inverter Application

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Copper, 100 x 12 x 2mmBusbar:

Closed U8mm, MumetallShield:

91205HF( 20/25mT)Chip:

001Number:

Demonstrator 200AName:

� 2-D FEM Simulation

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� Nonlinearity vs. Current

-2500

-2000

-1500

-1000

-500

0

500

1000

1500

2000

2500

-250 -200 -150 -100 -50 0 50 100 150 200 250

Current [A]

Sensor

Outp

ut

[mV

]

-0.5

-0.4

-0.3

-0.2

-0.1

0

0.1

0.2

0.3

0.4

0.5

Nonlin

earity

[%

FS

]

91205HF [mV] NL [%FS]

Sensitivity: 10.0 mV/A

Hysteresis: 2 mV => 0.2A => 0.1% F.S

Nonlinearity: ± 0.3% FS, FS = 200 A

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� Response Time

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

100 1000 10000 100000

Frequency [Hz]

No

rma

lize

d o

utp

ut

[ ]

0

10

20

30

40

50

60

70

80

90

100

110

120

Ph

as

e [

de

g]

Normalised output [ ] Phaseshift [deg]

� Frequency Response

Response Time : < 10 usec.

Frequency range: 50-100 kHz

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Summary IMC Current Sensors

IMC Current Sensor (IMC= integrated magnetic concentrator)

- Small size and low cost

- Simple construction

- High Bandwidth BW <100kHz

- Robust, Over current resistant

- High modularity by design

- Standard assembling technique on pcb

- non intrusive contact-less

Target Markets: Current Monitoring from few Amps to up to 1000 Amps on Bus Bar.

� Automotive (HEV, EV)

� Power Converter, Inverter, Motor Driver

� Battery Monitoring Sensor

� Over current protection, Electronic fuses,..

contact-less, small, robust and economical solution!

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Thank you

A Novel Contact-less Current Sensor for HEV/EV and Renewable … · Tria⊗⊗s⊗i => IMC...

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Transcript of A Novel Contact-less Current Sensor for HEV/EV and Renewable … · Tria⊗⊗s⊗i => IMC...