Addressing increased demand for highly accurate busbar current sensing solutions in industrial and automotive applications, Molex has launched its Percept current sensors that are up to half the size and 86% lighter than competing busbar current sensing solutions. This enables higher-density packaging, resulting in a reduction of overall system weight and greater design flexibility.
Joining Molex’s Percept family of sensors, the new current sensors leverage Infineon’s high-precision coreless current sensors and Molex’s proprietary electronics packaging technology to reduce sensor size and weight, while simplifying installation and system integration.
(Source: Molex)
The current sensors provide accuracy within 2% across a wide temperature range and entire product lifespan, with low sensitivity and offset errors. The operating temperature range is -40°C to 125°C. Other specs include a current range from +/-450.0 A to +/-1,600.0 A and a supply voltage range of 4.5 V to 5.5 V as well as full differential and single-ended outputs and bidirectional sensing.
The current sensors deliver more precise current measurement and higher immunity to electromagnetic interference thanks to the differential Hall-effect design of the coreless current sensors, suppressing noise from stray magnetic fields in electric vehicle and motor drive applications, Molex said.
The proprietary electronics packaging technology enables the integration of high-current conductors, connectors, printed circuit boards (PCBs), busbars and heat sinks, as well as other mechanical components, into a single device. This capability makes the technology suited for assemblies that must withstand high temperatures, high currents and harsh environments, Molex said.
The Percept current sensor line offers configurable design options, including a sensor-in-busbar design that provides a complete package for plug-and-play deployments. The industrial-grade current sensors are available with the busbar as a standard, pre-calibrated package that is suited for industrial, commercial and electric power applications. The automotive-grade versions will be available for drop-in installation into automotive busbars and validated for harsh automotive applications.
Pre-calibrated systems offer simpler and streamlined installation and can dramatically speed assembly time, Molex said.
The packaging technology also uses 99% less water than typical PCB manufacturing and does not require any chemicals or generate copper sludge, for a more environmentally friendly manufacturing method, according to the company.
The Percept current sensors are available in industrial- and automotive-grade options. Sensors for industrial applications will be available in October 2024, followed by automotive application product approval in the first half of 2025. Limited engineering samples are available now for industrial applications.
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