CURRENT SENSING IN POWER ELECTRONICS
Using precise current & voltage sensing as a central
physical value input to reach better efficiency
PRECISION MEASUREMENT
COMPANY
PRECISION MEASUREMENT
Our history
1482 First recorded reference to the “Kupferhütte auf der Nanzenbach“
1728 Name changed into “Isabelle Kupferhütte“
1827 Ownership of Isabellenhütte passes to the Heusler family
1889 MANGANIN® alloy developed
1952 Establishment of thermoelectric and resistance alloy division
1978 Establishment of components division
2008 Establishing of “Precision Measurement“ division
2010 Acquisition of our long-term US agency ISOTEK:
Isabellenhütte‘s first subsidiary
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
COMPANY
PRECISION MEASUREMENT
Location Dillenburg
Made in Germany
Despite being a global technology leader, we
have remained loyal to our roots in Dillenburg.
For a company such as ours, with enormous
expertise in both design and manufacturing,
Germany remains a highly attractive location.
Wilhelm van Oranje,
Born April 14th or April 24th 1533
in Dillenburg
Source Wikipedia
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
INNOVATION BY TRADITION
PRECISION MEASUREMENT
Content
1. Current measurement technologies
2. Influence factors for selecting current sensing principles
3. Physical basics of Shunt-based current measurement
4. Shunt-based solutions for different applications
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
CURRENT MEASUREMENT TECHNOLOGY
PRECISION MEASUREMENT
Shunt
Rogowski Spool
CURRENT MEASUREMENT TECHNOLGY
current
voltage
drop
Open Loop
HALL - Effect
Source. www.bodospower.org
Close Loop
HALL - Effect
Source. Wikipedia
FLUX-GATE
Source. www.powerguru.org
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
Source. www.powerguru.org
CURRENT MEASUREMENT TECHNOLOGY
PRECISION MEASUREMENT
Measurment principles
Magnetic (Hall, MR, Flux Gate)
Open loop
Closed loop
Inductive (Rogowski)
Optical
Restistive (Shunt based)
CURRENT MEASUREMENT TECHNOLGY
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
CURRENT MEASUREMENT TECHNOLOGY
PRECISION MEASUREMENT
Shunt-based method wins in respect of precision und cons. of TCO
HALL-EFFECT
FLUX-GATE
SHUNT-BASED
- accuracy
total
1,5 % of rg.
0,05 to 1% of rg.
0,1 % of rdg.
noise
high
low to medium
low
offset over temperature
medium
low to medium
low
linearity error
high
low to medium
very low
long time stability
medium
High
very high
possible
possible
not possible
saturation
CURRENT MEASUREMENT TECHNOLGY
Total cost of ownership
low
high
Further feature of Shunt-based measurement method is
additional voltage measurement on PCBA
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
low
INNOVATION BY TRADITION
PRECISION MEASUREMENT
Content
1. Current measurement technologies
2. Influence factors for selecting current sensing principles
3. Physical basics of Shunt-based current measurement
4. Shunt-based solutions for different applications
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
INFLUENCE FACTORS FOR THE SELECTION OF A MEASURMENT PRINCIPLE
PRECISION MEASUREMENT
Accuracy
Reaction time
Temperature range
Long time stability
Dynamic range
Overload
Design space
Noise immunity
Complexity of positioning in systems
Power dicipation and power use
Bandwith
Galvanic isolation
Cost (TCO)
INFLUENCE FACTORS FOR THE SELECTION OF A MEASURMENT PRINCIPLE
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
INNOVATION BY TRADITION
PRECISION MEASUREMENT
Content
1. Current measurement technologies
2. Influence factors for selecting current sensing principles
3. Physical basics of Shunt-based current measurement
INNOVATION
BY TRADITION
4. Shunt-based
solutions
for different applications
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
PHYSICAL BASICS OF SHUNT-BASED CURRENT SENSING
PRECISION MEASUREMENT
Current Measurement Technology: Shunt-based Current Sensing
A current which flows through an electrical conductor, causes several physical
effects:
Magnetic Induction / Magnetoresistive effect / Farady effect / Hall effect / Ohm’s law
Georg Simon Ohm observed during his experiments
withBASICS
electrochemical
cellsCURRENT
in the year
1821
PHYSIKAL
OF SHUNT BASED
SENSING
“current and the hereby produced voltage drop
over a resistor are proportional to each other”
U= R*I
or
Shunt
I=U/R
voltage
drop
ideal voltage
measurement
ideal resistor
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
current
OHM LAW INFLUENCES OF THE READING VALUE
PRECISION MEASUREMENT
U = R * I + Uth + Uoffset + Uind + Uiext + …
Uth
Uoffset
Uind
Uiext
OHM LAW INFLUENCES OF THE READING VALUER
:
:
:
:
Thermo Electric Voltage
Voltage Offset of Amplifier
parasitic, indicated Voltage
Voltage drop at circuit path of PCB
= R (T, t, U, A, µ, p, P, Hz, ....)
Georg Simon Ohm
1789 -1854
Source: www.peoplecheck.de
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
OHM LAW INFLUENCES OF THE READING VALUE
PRECISION MEASUREMENT
Real world: No ideal voltage measurement and no ideal resistance
U = R * I + Uth + UOffset + Uind + Uiext + …
Uth
: thermal
UOffset
: offset voltage of the electronic
Uind
: parasitic, induced voltage
OHM LAW INFLUENCES
OF
READING
VALUE
Uiext
: THE
voltage
drop
on PCB
tracks
R = R (T, t, A, µ, p, P, f, ....)
T
: Temperature
t
: time
A
: area (cross section)
µ
: permeability
p
: density
P
: Power
f
: frequency
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
Source: www.sengpielaudio.de
BASE METAL
PRECISION MEASUREMENT
Resistance materials
BASE METAL
Application of Thermoelectric and Resistance Alloys
Antifreeze
Heating
Temperature measurement and controlling
Current sensing and limitation
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
RESISTANCE ALLOYS
PRECISION MEASUREMENT
Cu Zn
Alloys
Cu
Alloys
RESISTANCE ALLOYS
Met. Resistance
Basic Materials
Cr/Ni-Alloys
Thermoelectric voltage
Cu Ni
Alloys
Isotan
Cu Mn
Alloys
Manganin
Fe free Cr/NiAlloys
Fe containing
Cr/Ni- Alloys
Zeranin
Noventin
IsaOhm
K-Order
Application
Fe/Cr (Si)Alloys
Heating
Tech. Resistors
Precision Resistors
Soldering materials
Pressure Sensors
Fe/CrAlloys
Fe/Cr AlAlloys (l)
Fe/Cr AlAlloys (h)
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
Ferromagnetism
Embrittlement
Aluchrom
INNOVATION BY TRADITION
PRECISION MEASUREMENT
Content
1. Current measurement technologies
2. Influence factors for selecting current sensing principles
3. Physical basics of Shunt-based current measurement
4. Shunt-based solutions for different applications
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
SHUNT BASED CURRENT MEASUREMENT
PRECISION MEASUREMENT
5 arguments for ISAscale® Shunt-based measurement
Arguments
Details
1. High precision
-
2. Wide dynamic range
- High power apps (up to 20kV, 30kA)
- No saturation effects over dynamic rangeHigh power
apps (up to 20kV, 30kA)
- No saturation effects over dynamic range
SHUNT BASED CURRENT MEASUREMENT
No temperature drift
Low Offset High linearity (<0,01% of rng)
High resolution (up to 16bit)
High immunity to stray magnetic fields
Long time stability
3. High functionality
-
Current & Voltage measurement with only one device
Redundant measurement channels
Temperature measurement
Current / energy counters
Software & Hardware Trigger
Software & Hardware Ov
4. Digital Interface
- Plug & Play
- High controllability / accessability
- Easy data storage (log
5. Compact design
− Low weight and size also for high current / high
precision applications
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
SHUNT BASED CURRENT MEASUREMENT
Application fields
SHUNT BASED CURRENT MEASUREMENT
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
PRECISION MEASUREMENT
SHUNT BASED CURRENT MEASUREMENT
PRECISION MEASUREMENT
ISAScale®‘s 6 major product families
Product Families
Picture
IVT family
ISAscale ® / Current Voltage Temperature
Application: Battery Management System (Li-Ion), Fuel Cells
ICD familiy
NEW
ISAscale ®
Compact Digital
Application: Compact current sensor family for DC currents
IPC familiy
ISAscale ® Phase Current
Application: Phase Current Measurement in UPS, Inverter, Power Supply…
ILF family
NEW
ISAscale ® Integrated Lead Frame
Application: Ultra-compact current sensor with analog output for SMD mount
IHC familiy
SHUNT BASED CURRENT MEASUREMENT
ISAscale ® High Current
Application: Mixed current measurement (AC&DC), Renewable energy, Power supplies,...
IHI familiy
ISAscale ® High Isolated
Application: Medium Voltage Phase Current and Voltage Measurement in High Power
Inverter, Power Supply…)
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
SHUNT-BASED CURRENT MEASUREMENT
PRECISION MEASUREMENT
Application: Battery Sensing (SOC; SOH, SOF)
Measurement of low frequent current with high precision
Source: www.openclipart
Functionalities
Offsetfree Measurement (Samp. Rate 1–8 kHz
SHUNT BASED CURRENT MEASUREMENT
Digital Communication (CAN, SPI)
Nominal range 100 A – 2500 A
With and without galvanical Isolation
Over Current detection
Digital to parametrise
Diagnostics
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
Source: www.wikimedia.org
SHUNT BASED CURRENT MEASUREMENT
PRECISION MEASUREMENT
Application: Phase Current Sensing
Measurement of phase current in Inverter and electrical engines
Functionalities
Source: Semikron
• Conversion with Sigma-Delta-Modulator
SHUNT BASED CURRENT MEASUREMENT
• System frequency 10 – 20 MHz
• Datarate 78 kHz (16 Bit), 300 kHz (12 Bit)
• Overcurrent detection
• With or without digital filtering
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
SHUNT BASED CURRENT MEASUREMENT
PRECISION MEASUREMENT
Measuring at high electrical potential differences
Measuring of current and voltage in medium voltage equipment
Functionalities
Digital current and voltage sensing
Central evaluation unit
Working voltage up to 24KV
Calculation of derived values
Communication via Ethernet
Measuring principle by Sigma-Delta
Modulator
Precision Measurement
Patent pending: PCT/EP2013/000542
Isabellenhütte Heusler GmbH & Co. KG Dillenburg
Jens Hartmann June 2015
Thank you for your attention.
QUESTIONS ?
Referent // Monat Jahr
ISABELLENHÜTTE HEUSLER GMBH & CO. KG
Jens Hartmann
Sales Director ISAscale®
Mail: jens.hartmann@isabellenhuette.de
Phone: 0049 2771 934 250
ISABELLENHÜTTE HEUSLER GmbH & Co. KG
Eibacher Weg 3-5
35683 Dillenburg
Germany