A CURRENT MEASUREMENT CIRCUIT

Abstract

A current measurement circuit suitable for measuring the flow of current along a path in an electrical circuit such as a part of an electric power assisted steering system comprises a current measurement resistor that is located in series in the electrical path through which a current to be measured may flow, a first measurement sub-circuit that measures the voltage dropped across at least a part of the resistor and produces a first output signal, and a second measurement sub-circuit that measures the voltage dropped across at least a part of the resistor and produces a second output signal, and in which the electrical connections of the two sub-circuits to the resistor are independent of each other.

Claims

1.-15. (canceled)

16. A current measurement circuit suitable for measuring the flow of current along an electrical path in an electrical circuit such as a part of an electric power assisted steering system, the current measurement circuit comprising: a current sense resistor that is located in series in the electrical path through which a current to be measured flows; a first measurement sub-circuit that measures the voltage drop across at least a part of the resistor and produces a first output signal; and a second measurement sub-circuit that measures the voltage drop across at least a part of the resistor and produces a second output signal, and in which the electrical connections of the two sub-circuits to the current measurement resistor are independent of each other.

17. The current measurement circuit according to claim 16 in which the two sub-circuits are fully independent in that they have no shared electrical components.

18. The current measurement circuit according to claim 16 in which each sub-circuit includes an amplifier circuit and in which the amplifier circuit of one sub-circuit is independent of the amplifier circuit of the other sub-circuit.

19. The current measurement circuit according to claim 16 that includes a controller that, in use, processes the output of the two sub-circuits to provide a single current measurement.

20. The current measurement circuit according to claim 19 in which the controller, in use, sets the single current measurement to be equal to the first output signal unless a fault is detected, and in the event that the fault is detected the controller switches the single current measurement to be equal to the second output signal.

21. The current measurement circuit according to claim 16 that further includes a fault detection circuit that monitors the first and second output signals to detect a fault.

22. The current measurement circuit according to claim 16 in which the first and second measurement sub-circuits measure the voltage drop across different parts of the current sense resistor and from this measurement produce the first and second output signals.

23. The current measurement circuit according to claim 16 that includes a circuit board which is provided with electrical tracks to which the current sense resistor is attached, the board carrying the first and second measurement sub-circuits, each sub-circuit being connected to the current sense resistor using electrical connections that are not shared with the other sub-circuit.

24. The current measurement circuit according to claim 22 in which the electrical connections of each sub-circuit to the current sense resistor comprise soldered joints to legs that are an integral part of the current sense resistor.

25. The current measurement circuit according to claim 24 in which each of the first and second measurement sub-circuits is connected to a pair of legs of the current sense resistor that are not shared with the other measurement sub-circuit.

26. The current measurement circuit according to claim 25 in which the input to the current sense resistor and the output of the current sense resistor that connect it in series into the electrical path along with the current is to be measured comprise legs which are not shared with the legs that the current measurement circuits are connected to.

27. The current measurement circuit according to claim 16 in which the current sense resistor comprises an electrically conductive element that is formed into a U-shape to define two wings joined at a ridge, each wing being provided with four legs along an edge opposite the ridge for connection to the sub-circuits to a first part of the path along which current is to be measured and to a second part of the path that is on the electrically opposite side of the resistor.

28. A current sense resistor for use in a current measurement circuit comprising an electrically conductive element that is provided with at least eight legs, each leg defining a connection point by which the current sense resistor is connected to the current measurement circuit through an electrically conductive joint, in which the legs are located on the electrically conductive element in pairs such that an electrical path of known resistance is present between each leg of a pair.

29. The current sense resistor according to claim 28 in which the legs are positioned such that the electrical paths through the element between each pair are different.

30. The current sense resistor according to claim 28 that comprises an element that forms a U-shape defining two wings joined at a ridge, each wing being provided with four legs along an edge opposite the ridge for connection to a plurality of sub-circuits of the current measurement circuit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] FIG. 1 is a simple block diagram of a current measurement circuit that falls within the scope of the first aspect of the invention;

[0045] FIG. 2 is a perspective view of a current sense resistor that can be used in the circuit of FIG. 1;

[0046] FIG. 3 shows the element flattened out;

[0047] FIG. 4 shows the connections made to each of the eight legs of the current sense resistor; and

[0048] FIG. 5 is a diagram showing a typical application of the current measurement circuit of FIG. 1 in an electric power assisted steering system; and

[0049] FIG. 6 is an electrical representation of the resistor and the contacts.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0050] FIG. 1 shows a current measurement circuit 100 that falls within the scope of the first aspect of the invention. The circuit comprises a current measurement resistor 110 that is located in series in a path along which current is to be measured (Question—have I drawn this correctly?). The current in FIG. 1 enters on the left as i.sub.in and exits on the right as i.sub.out.

[0051] The resistor 110, which will be described in more detail later and is represented electrically in FIG. 6, comprises a single element that carries 8 conductive legs, 111-118, the legs forming pairs between which a path of known resistance is present. The path in this example has a resistance R.

[0052] The current measurement circuit includes two sub-circuits 120,130, each of which measures the voltage dropped across the resistive path. Typically the sense resistor 110 is provided in the current flow path of the motor purely for this purpose, in series with an active system, and will be of a high tolerance and of known resistance. It is preferred that the resistance along each path between pairs of legs is small so that it has little impact on the overall voltage available for the active circuit, for example of the order of 1 mOhm or less.

[0053] Two voltage inputs, V.sub.1,1′ and V.sub.2,2′ are taken from each side of the resistor R. Each of the voltages V.sub.1,1′, V.sub.2,2′ is fed to a respective input of each sub circuit. As shown each sub circuit 120,130 comprises a differential amplifier formed from an Op-amp. The output of one sub-circuit, Isense1 will be proportional to the current, and the output of the other sub-circuit, Isense2, will also be proportional to the current. The resistor comprises a single resistive element with two pairs of sense connections.

[0054] The two signals are fed into a controller 140 that includes a fault diagnostic circuit 150. The controller monitors the two signals, and unless a fault is flagged by the fault diagnostic circuit it uses ISENSE_1 as the primary output of the current measurement circuit.

[0055] The diagnostic circuit may apply a diagnostic test to each of the sub-circuits to determine if one or both are faulty. For instance, an offset voltage may be applied to one or both inputs to the differential amplifier (where used) of each sub-circuit, and the behaviour of the output of the amplifiers observed to determine if there is a fault.

[0056] If the offset test indicates a problem with ISENSE_1, then the system will transfer to ISENSE_2 for the output of the current measurement circuit. ISENSE_2 is also equipped with the same offset test as ISENSE_1, and when control has been transferred to ISENSE_2, the offset test will be transferred to ISENSE_2 to monitor the correct operation of this amplifier channel. If the offset test then reveals a problem with the ISENSE_2 amplifier, then the system will transition to a further reversionary mode of operation, described below.

[0057] Because ISENSE_1 and ISENSE_2 are derived from different legs of the current sense resistor, there are no single point failure modes that are common to both sub-circuits. This removes the common single point failure modes of the sense connections and associated signal paths of prior art circuits. The two sub-circuit share no common components or common electrical paths, and do not share legs of the resistor or common soldered joints.

[0058] FIGS. 2 to 4 show a suitable sense resistor element 110 in detail. The element may be formed by bending a flat metal element into U-shape which has two wings 160,170 that meet at a ridge, the free edge of each wing carrying four of the eight legs. FIG. 2 shows the folded resistor, and FIG. 3 shows it flattened before folding. As shown the wings are each planar and lie parallel to one another, extending away from the circuit board at 90 degrees to the board to minimise the amount of real estate used on the circuit board. This shape also helps with cooling as air can flow easily over the resistor 110. Additionally, the low enclosed area of the sense resistor minimises its self-inductance which is beneficial if the measured current signal is rapidly changing.

[0059] FIG. 4 shows the location of the electrical connections from the sense resistor element to the two sub-circuits and to the input and output sides of the path along which the current to be measured is flowing. The arrows in FIG. 4 represent the resistance measurement points, a leg being provided at each of these points.

[0060] The current measurement circuit is especially suited for use in monitoring the current flowing in a motor of an electrical system such as an electric power steering system. FIG. 5 is a block diagram of one such suitable application.

[0061] A motor, which applies an assistance force to a part of a steering system, is driven by a motor bridge circuit that is controlled by a motor bridge driver that receives pulse width modulated signals from a motor controller. The two sub-circuits are integrated with the motor bridge circuit and may as shown share a common circuit board and heat sink (not shown).

[0062] The current sense resistor 110 is placed in the path of current flowing in the motor, and the output of the current measurement circuit is fed to the motor controller.

[0063] In the event of failure of both current sensing amplifier channels ISENSE_1 and ISENSE_2, detected by the diagnostic circuit of the current measurement circuit, the system motor controller may initially move to a ‘voltage control’ operating mode that does not depend on measurement of the motor current. However, due to the complete independence of the two sub-circuits which share no common parts, it is expected that such a fault event would be very unlikely to arise.

[0064] The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.