**Keywords: electric vehicle current sensor, motor control, BMS battery management**
Electric vehicles have become increasingly popular in recent years, entering millions of households. They come in various forms, from two-wheeled electric bicycles to three- and four-wheeled low-speed vehicles, as well as four-wheel EV models, electric buses, and electric trucks. While the basic application methods are similar across these types, the demand for sensors varies significantly. Low-speed vehicles often use simple shunts or Hall sensors, which are cost-effective but may lack the safety and precision required for more advanced systems.
This article provides an overview of the application methods and product types of current sensors in electric vehicles. Compared to traditional sensors, modern current sensors offer advantages such as high stability, accuracy, and resistance to extreme temperatures.
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**1. Introduction**
Electric vehicles (EVs) have evolved rapidly over the past decade, with a wide range of applications and increasing adoption. The most common types include two-wheeled electric bikes, three- and four-wheeled low-speed vehicles, and higher-end four-wheel EVs. Despite their differences, they all rely on key components like current sensors to monitor and manage energy flow efficiently.
In many low-speed electric vehicles, the use of basic shunts or Hall sensors is common due to their simplicity and low cost. However, this can lead to issues with reliability and safety. This article focuses on the selection and proper use of current sensors, particularly in electric buses and household electric cars, where performance and safety are critical.
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**2. Principle of Hall Current Sensor**
Most current sensors used in electric vehicles today are open-loop Hall current sensors. These sensors operate based on the direct measurement principle of the Hall effect. The magnetic flux generated by the primary current is collected by a high-quality magnetic core. A Hall element detects the magnetic field in a small air gap, and the resulting voltage is processed to provide an accurate representation of the primary current.
Compared to closed-loop sensors, open-loop sensors offer better cost-effectiveness, compact size, and improved temperature resistance. Their internal structure is simpler, contributing to higher reliability.
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**3. Characteristics of Hall Sensors**
Regardless of whether they are open-loop or closed-loop, Hall sensors share several key advantages:
- Fast response time
- Low temperature drift
- High measurement accuracy
- Compact size
- Strong overload capability
These features make them ideal for use in various automotive applications, especially in environments where precision and durability are essential.
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**4. Types of Electric Vehicle Current Sensors**
Current sensors in electric vehicles are primarily divided into two categories: those used in the BMS (Battery Management System) and those used in the motor controller. Some models can be shared between the two systems, depending on design choices and market demands.
**BMS Battery Management System:**
- **JKC39I**: Single-supply, single-range sensor requiring 5V power.
- **JKC1I**: Dual-power, dual-range sensor requiring ±12–15V DC power.
- **JKC5I**: Single-supply, dual-range sensor with two Hall elements and two magnetic cores for enhanced accuracy.
These sensors are widely used in low- and medium-speed vehicles, with JKC39I being particularly popular due to its high reliability.
**Motor Controller Application:**
- **JKC39I**, **JKC1I**, and **JKP9I** are commonly used in motor controllers.
- **JKP9I** is notable for its simple structure and high reliability, as it requires no PCB processing circuit and relies solely on the Hall chip and magnetic ring.
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**5. Comparison and Structure of Current Sensors**
The structure of current sensors plays a significant role in their performance and reliability. For example, the **JKC1I** has a more complex PCB with around 20 electronic components, which can reduce overall reliability. In contrast, the **JKP9I** has a minimalistic design with just a Hall chip and magnetic core, making it more reliable and easier to maintain.
Testing has shown that even at high temperatures (up to 170°C), the failure rate of these sensors is very low, as other components in the vehicle would likely fail first.
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**6. Key Considerations When Selecting and Using Current Sensors**
When selecting and using current sensors, several factors should be considered:
- Ensure the sensor’s hole size allows for proper wire passage, and consider using copper bars for easier installation and maintenance.
- Verify that the space and structural requirements are met.
- Pay attention to wiring procedures, especially avoiding ESD (electrostatic discharge) and ensuring correct connections for power, input, and output.
- Choose a clean, non-conductive environment free from dust and corrosive substances.
- Ensure the conductor is centered within the sensor's hole to minimize position errors.
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**7. Conclusion**
As government subsidies for new energy vehicles decline, the competition in the EV market becomes fiercer. Reducing hard costs, ensuring product reliability, and shortening production cycles are now top priorities for manufacturers. Current sensors play a crucial role in both the BMS and motor control systems, making them essential components in electric vehicles.
At Beijing Jinsheng Yuanchuang Electronic Technology Co., Ltd., we understand the importance of these components and are committed to providing high-quality solutions. For more information about our products, feel free to visit our website or contact us directly.
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