Recommendations and Typical Errors in Design of Power Converter PCBs With Shunt Sensors

Abstract

Nowadays the percentage of power electronic devices, which use shunts for sensing of electrical signals, is increasing significantly. This method of measurements is simple, reliable and low-cost, however it requires careful elaboration of schematics and meticulous design of printed circuit boards. The author provides a detailed insight into the design of power converter Printed Circuit Boards (PCBs) with shunt-based sensing circuits and provides recommendations on improvement of signal measurements. He analyses the most popular design mistakes and illustrates their impact on measuring signals, which can be used for mistake localization. This paper demonstrates that the properly designed schematic can be turned into poorly operating PCB and recommends measures to avoid it. The author shares his more than 20-years experience and illustrates his statements with examples from real life. Although this paper is mainly addressed to young engineers, it could also be useful for experienced researchers, who work in neighboring areas and do not gain experience in PCB design.

High-Current Sensing Technology for Transparent Power Grids: A Review

“…However, its high cost and temperature effects are not negligible, so its accuracy needs to be evaluated by corresponding standards and methods, such as magnetic bridge current sensors and electronic current transformers [13], [14]. To evaluate the frequency and current dependence of shunt resistors at different AC levels, a modified current-bridge method was developed by Kon and Yamada [15] based on 100 squirrel-cage shunt resistors connected in parallel with 10 Ω foil resistors. These researchers investigated the influence of the temperature rise of resistors at different ACs on the uncertainty of the current measurement, thus extending the shunt's measurement frequency and current range [15].…”

“…To evaluate the frequency and current dependence of shunt resistors at different AC levels, a modified current-bridge method was developed by Kon and Yamada [15] based on 100 squirrel-cage shunt resistors connected in parallel with 10 Ω foil resistors. These researchers investigated the influence of the temperature rise of resistors at different ACs on the uncertainty of the current measurement, thus extending the shunt's measurement frequency and current range [15].…”

Design of Fluxgate Current Sensor Based on Magnetization Residence Times and Neural Networks

“…A variety of current sensors, grounded in principles such as Ohm’s law and Faraday’s law of induction, play a pivotal role in accurately measuring current flow in circuits. These include shunt resistors [ 6 ], current transformers [ 7 ], Rogowski coils [ 3 ], Hall effect sensors [ 8 ], fluxgate sensors [ 4 ], magnetoresistive sensors [ 9 ], and fiber optic sensors [ 10 ]. Among them, fluxgate current sensors, recognized for their superior sensitivity and minimal thermal drift, are extensively employed across various industries, including automotive, power electronics, smart grids, and industrial automation [ 4 ].…”

Comparison of Feedback Field-Weakening Techniques for Synchronous Machines with Permanent Magnets

“…One of the results of the activity in this direction was the significant rise of electrical cars' market share [10,11], which in turn intensified the development in neighboring areas, which includes electric motor drives [12], batteries as well as technologies connected to them [13][14][15], power electronics, etc. [16].…”