Back pain is one of the main causes of everyday discomfort and sick leave in the western world. The reason for this is often a lack of exercise in the sedentary office routine combined with a lack of compensatory activities such as sport and gymnastics. The aim of the spin-off StraightUp by three graduates of the Karlsruhe Institute of Technology (KIT) is to combat back pain in the long term and sustainably with an innovative idea. To this end, they have developed a wearable textile product that uses woven elastic wires and appropriate sensors to measure the shoulder position and inclination of the back and ensures a sustainable improvement in posture through haptic feedback.Previous posture stabilizers are designed to simply fix the back, which in the long term severely limits the mobility of the user. Other approaches with built-in inclination sensors that trigger a vibration impulse when the body bends forward have the disadvantage that many everyday and sports activities take place in a forward-leaning position and thus lead to incorrect vibration impulses.<h2>Novel approach using elastic metal alloy and AI implementation</h2>The spin-off StraightUp is tackling this problem with an innovative idea. Erik Vautrin, Marcus Hamann-Schroer and Jan Bartenbach, three KIT graduates, in collaboration with physiotherapist Tobias Baierle, developed the vision of a wearable textile that can measure the shoulder position and inclination of the back using elastic wires incorporated into the fabric. Using the data obtained from this and a woven-in chip controlled by artificial intelligence (AI), the system generates haptic feedback through vibrations, which is intended to encourage users to correct their posture. The use of the sensors in the wearable was made possible by a conductive super-elastic metal alloy that adapts to the movements of the person wearing it. "Through the haptic feedback, the body learns to maintain a healthier posture on its own, which leads to long-term improvement. The feedback system promotes active shoulder blade stabilization and posture correction of the spine," explains Baierle. The wearable can be worn in everyday life as well as during leisure and sports activities.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1726101689229-2024_069_Innovatives+Wearable_Koerperhaltung+nachhaltig+verbessernBild2_72dpi.jpg" style="width: 100%px;" class="fr-fic fr-dib">Sustainable support for the back: StraightUp's concept relies on sensors, AI and haptic feedback. (Photo: StraightUp)<h2 id="isPasted">Further steps on the way to spin-off and market readiness</h2>The team is currently working with the German Institute for Textile and Fiber Research to enable the best possible integration of the sensors into the wearable. "This partnership brings us a big step closer to market readiness," explains Vautrin. In collaboration with doctors, physiotherapists and other specialists, optimization tests are to take place this year. The aim is to test the further developed product with potential customers at the end of the year.<h2>Support for founders at KIT</h2>The three founders of StraightUp met in the course “Microsystem product design for young entrepreneurs” at KIT. “In the course we learned the basics of developing and implementing a product idea. We also learned practical things like writing a business plan,” explains Bartenbach. The young team then met the physiotherapist Baierle through a lecturer.On their journey so far, the founders have used the support options at KIT. These include the KIT start-up forge and other offers from the KIT's Innovation and Relations Management (IRM) service unit. With the support of IRM, the StraightUp team successfully acquired an EXIST start-up grant for preparation and early-stage financing of the upcoming spin-off. "From the very beginning, we had a great impression of the competence of the individual people and how they interact with each other in the StraightUp team," says Dr. Rolf Blattner, Business Development Manager at IRM.&nbsp;

In the future, StraightUp could improve posture in everyday office life and thus reduce back pain, as demonstrated here in the prototype. (Photo: StraightUp)

KIT spin-off StraightUp aims to permanently relieve posture-related back pain

Innovative Wearable: Sustainably Improving Posture

<h2 id="isPasted">Enhancing Security Using the Latest Technology</h2>Security is a topic on everyone’s minds today, and as technology gets more advanced, it can be easier to bypass the older systems that others have built. Large-scale system hacks are highly publicized and can affect a wide range of people, but smaller scale hacks can be just as devastating. Therefore, it’s essential to use the best technology to protect what matters most, such as your home and family. Face recognition can provide a more effective home security solution than traditional keys and keypads. Physical keys can be duplicated, stolen, lost, or forgotten, and key codes can be guessed, forgotten, or shared with unauthorized users. Accurate face recognition technology has none of those disadvantages, and owners can easily manage the authorization of each person and log their entries.With some of these legacy security systems becoming easier to bypass, we need to constantly develop new solutions using the latest technology to keep the highest level of security. This is where the smart door lock, utilizing machine learning and 3D facial recognition from AMD technology partner Makarena Labs, comes into play. In this blog, we discuss how smart door technology is bringing peace of mind to the front door and more with a superior level of security.<h2>Addressing Current Security Problems in Smart Door Locks</h2>Smart door locks can provide increased protection for homes and other consumer dwelling spaces, like garages or sheds, but previous versions of smart locks can be easily tricked. Due to the incorporated technology—generally a standard CMOS sensor—previous smart locks can be fooled into opening by using 2D pictures of an authorized person’s face. This results in a false recognition and the system will allow an unauthorized person entry, which is a major security breach that needs to be addressed. &nbsp;AMD, in partnership with Makarena, have developed a capable solution, based on the AMD <a href="https://www.mouser.com/new/xilinx/xilinx-zynq-7000-socs/" target="_blank">Zynq™ 7000 SoC</a>, that provides a fully functional and robust design using 3D facial recognition. This advanced facial recognition is achieved through a camera that uses IR Time-of-Flight (TOF) or Lidar technology to bounce a pattern off the face of the person attempting to gain entry, while the sensors in the smart lock capture the reflection (Figure 1).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725853250211-Figure_1_Makarena_Labs_Smart_Lock.png" style="width: 100%px;" class="fr-fic fr-dib">Figure 1: This smart lock design, developed by AMD and their partner Makarena, is based on the AMD Zynq 7000 SoC, incorporates IR TOF or Lidar technology to detect and create a 3D map of the face, and compares the 3D map to the authorized users in the system, only unlocking if a match is found. (Source: AMD)Using the reflection captured by the sensors, the system creates a 3D map of the face and compares it to the authorized users in the system, only unlocking if a match is found (Figure 2). The CMOS sensor provides an added layer of accuracy and simplifies user management for the homeowner by providing images of each authorized user.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725853270469-Figure2_Detection_authorization_process.webp" style="width: 100%px;" class="fr-fic fr-dib">Figure 2: The smart door lock’s detection and authorization process ensures accuracy while simplifying user management. (Source: AMD)This advanced smart door lock system also works in complete darkness and can recognize authorized people even while they are wearing glasses, hats, or facial covers.The AMD Zynq 7000 SoC design can be easily configured and customized by OEMs with help on hand from Makarena Labs, providing a lock that can store a family’s authorized faces and accurately authorize or reject them in under a second. For applications that need to store a larger number of faces, such as a neighborhood’s security gate, the higher performance AMD&nbsp;<a href="https://www.mouser.com/new/xilinx/xilinx-zynq-ultrascale-mpsocs/" target="_blank">Zynq UltraScale+™ MPSoC</a> can support fast recognition even with hundreds of authorized faces. Both parts include robust security engines, which OEM customers can configure to load only authentically signed, encrypted firmware.If you're interested in hearing more about the smart lock solution, please reach out to sales@makarenalabs.com.AMD, and the AMD Arrow logo, UltraScale+, Zynq, and combinations thereof are trademarks of Advanced Micro Devices, Inc.The <a href="https://community.amd.com/t5/adaptive-computing/smart-door-locks-enhancing-security-with-machine-learning/ba-p/583320" rel="noreferrer nofollow" target="_blank">Smart Door Locks – Enhancing Security with Machine Learning</a> blog was first published on amd.com and was reposted here with permission.<hr>Xilinx develops highly flexible and adaptive processing platforms that enable rapid innovation across a variety of technologies, from the endpoint to the edge to the cloud. Specializing in programmable logic devices, Xilinx is the semiconductor company that invented the Field Programmable Gate Array (FPGA), the hardware programmable System on Chip (SoC), and the Adaptive Compute Acceleration Platform (ACAP).

In this blog, we discuss how smart door technology is bringing peace of mind to the front door and more with a superior level of security.

Smart Door Locks - Enhancing Security with Machine Learning

For the past decade, disordered rock salt has been studied as a potential breakthrough cathode material for use in lithium-ion batteries and a key to creating low-cost, high-energy storage for everything from cell phones to electric vehicles to renewable energy storage.A new MIT study is making sure the material fulfills that promise.Led by Ju Li, the Tokyo Electric Power Company Professor in Nuclear Engineering and professor of materials science and engineering, a team of researchers describe a new class of partially disordered rock salt cathode, integrated with polyanions — dubbed disordered rock salt-polyanionic spinel, or DRXPS — that delivers high energy density at high voltages with significantly improved cycling stability.“There is typically a trade-off in cathode materials between energy density and cycling stability … and with this work we aim to push the envelope by designing new cathode chemistries,” says Yimeng Huang, a postdoc in the Department of Nuclear Science and Engineering and first author of a&nbsp;<a href="https://www.nature.com/articles/s41560-024-01615-6" target="_blank">paper describing the work published today in&nbsp;Nature Energy</a>. “(This) material family has high energy density and good cycling stability because it integrates two major types of cathode materials, rock salt and polyanionic olivine, so it has the benefits of both.”Importantly, Li adds, the new material family is primarily composed of manganese, an earth-abundant element that is significantly less expensive than elements like nickel and cobalt, which are typically used in cathodes today.“Manganese is at least five times less expensive than nickel, and about 30 times less expensive than cobalt,” Li says. “Manganese is also the one of the keys to achieving higher energy densities, so having that material be much more earth-abundant is a tremendous advantage.”<h2>A possible path to renewable energy infrastructure</h2>That advantage will be particularly critical, Li and his co-authors wrote, as the world looks to build the renewable energy infrastructure needed for a low- or no-carbon future.Batteries are a particularly important part of that picture, not only for their potential to decarbonize transportation with electric cars, buses, and trucks, but also because they will be essential to addressing the intermittency issues of wind and solar power by storing excess energy, then feeding it back into the grid at night or on calm days, when renewable generation drops.Given the high cost and relative rarity of materials like cobalt and nickel, they wrote, efforts to rapidly scale up electric storage capacity would likely lead to extreme cost spikes and potentially significant materials shortages.“If we want to have true electrification of energy generation, transportation, and more, we need earth-abundant batteries to store intermittent photovoltaic and wind power,” Li says. “I think this is one of the steps toward that dream.”That sentiment was shared by Gerbrand Ceder, the&nbsp;Samsung&nbsp;Distinguished&nbsp;Chair&nbsp;in Nanoscience and Nanotechnology Research and a professor of materials science and engineering at the University of California at Berkeley.“Lithium-ion batteries are a critical part of the clean energy transition,” Ceder says. “Their continued growth and price decrease depends on the development of inexpensive, high-performance cathode materials made from earth-abundant materials, as presented in this work.”<h2>Overcoming obstacles in existing materials</h2>The new study addresses one of the major challenges facing disordered rock salt cathodes — oxygen mobility.While the materials have long been recognized for offering very high capacity — as much as 350 milliampere-hour per gram — as compared to traditional cathode materials, which typically have capacities of between 190 and 200 milliampere-hour per gram, it is not very stable.The high capacity is contributed partially by oxygen redox, which is activated when the cathode is charged to high voltages. But when that happens, oxygen becomes mobile, leading to reactions with the electrolyte and degradation of the material, eventually leaving it effectively useless after prolonged cycling.To overcome those challenges, Huang added another element — phosphorus — that essentially acts like a glue, holding the oxygen in place to mitigate degradation.“The main innovation here, and the theory behind the design, is that Yimeng added just the right amount of phosphorus, formed so-called polyanions with its neighboring oxygen atoms, into a cation-deficient rock salt structure that can pin them down,” Li explains. “That allows us to basically stop the percolating oxygen transport due to strong covalent bonding between phosphorus and oxygen … meaning we can both utilize the oxygen-contributed capacity, but also have good stability as well.”That ability to charge batteries to higher voltages, Li says, is crucial because it allows for simpler systems to manage the energy they store.“You can say the quality of the energy is higher,” he says. “The higher the voltage per cell, then the less you need to connect them in series in the battery pack, and the simpler the battery management system.”<h2>Pointing the way to future studies</h2>While the cathode material described in the study could have a transformative impact on lithium-ion battery technology, there are still several avenues for study going forward.Among the areas for future study, Huang says, are efforts to explore new ways to fabricate the material, particularly for morphology and scalability considerations.“Right now, we are using high-energy ball milling for mechanochemical synthesis, and … the resulting morphology is non-uniform and has small average particle size (about 150 nanometers). This method is also not quite scalable,” he says. “We are trying to achieve a more uniform morphology with larger particle sizes using some alternate synthesis methods, which would allow us to increase the volumetric energy density of the material and may allow us to explore some coating methods … which could further improve the battery performance. The future methods, of course, should be industrially scalable.”In addition, he says, the disordered rock salt material by itself is not a particularly good conductor, so significant amounts of carbon — as much as 20 weight percent of the cathode paste — were added to boost its conductivity. If the team can reduce the carbon content in the electrode without sacrificing performance, there will be higher active material content in a battery, leading to an increased practical energy density.“In this paper, we just used Super P, a typical conductive carbon consisting of nanospheres, but they’re not very efficient,” Huang says. “We are now exploring using carbon nanotubes, which could reduce the carbon content to just 1 or 2 weight percent, which could allow us to dramatically increase the amount of the active cathode material.”Aside from decreasing carbon content, making thick electrodes, he adds, is yet another way to increase the practical energy density of the battery. This is another area of research that the team is working on.“This is only the beginning of DRXPS research, since we only explored a few chemistries within its vast compositional space,” he continues. “We can play around with different ratios of lithium, manganese, phosphorus, and oxygen, and with various combinations of other polyanion-forming elements such as boron, silicon, and sulfur.”With optimized compositions, more scalable synthesis methods, better morphology that allows for uniform coatings, lower carbon content, and thicker electrodes, he says, the DRXPS cathode family is very promising in applications of electric vehicles and grid storage, and possibly even in consumer electronics, where the volumetric energy density is very important.<hr>This work was supported with funding from the Honda Research Institute USA Inc. and the Molecular Foundry at Lawrence Berkeley National Laboratory, and used resources of the National Synchrotron Light Source II at Brookhaven National Laboratory and the Advanced Photon Source at Argonne National Laboratory. The work was carried out, in part, using MIT.nano’s facilities.&nbsp;

An artistic illustration of the integration between two distinct battery cathode structures, rock salt (blue polyhedra) and polyanion olivine (red/yellow polyhedra). A novel hybrid structure is obtained by integrating polyanions (yellow polyhedra) into a rock salt (blue polyhedra) structure. Photo: Yimeng Huang/Department of Nuclear Science and Engineering

A new family of integrated rock salt-polyanion cathodes opens door to low-cost, high-energy storage.

Study of disordered rock salts leads to battery breakthrough

Photovoltaics are set to meet over 40 percent of Switzerland’s electricity needs by 2050. But solar power isn’t always available when it’s needed: there’s too much of it in summer and too little in winter, when the sun shines less often and heat pumps are running at full tilt. According to the Swiss federal government’s Energy Strategy, Switzerland wants to close the winter electricity gap with a combination of imports, wind and hydropower as well as alpine solar plants and gas-fired power plants.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725320869826-image.imageformat.carousel.940179852.jpg" style="width: 100%px;" class="fr-fic fr-dib">ETH researchers Samuel Heiniger (left, with a jar of iron ore) and Professor Wendelin Stark in front of the three iron reactors on ETH Zurich’s Hönggerberg campus. (Image: ETH Zurich)One way to minimise the need for imports and gas-fired power plants in winter is to produce hydrogen from cheap solar power in summer, which could then be converted into electricity in winter. However, hydrogen is highly flammable, extremely volatile and makes many materials brittle. Storing the gas from summer until winter calls for special pressurised containers and cooling technology. These require a lot of energy, while the many safety precautions that must be followed make building such storage facilities very expensive. What’s more, hydrogen tanks are never completely leak-proof, which harms the environment and adds to the costs.Now researchers at ETH Zurich led by Wendelin Stark, Professor of Functional Materials at the Department of Chemistry and Applied Biosciences, have developed a new technology for the seasonal storage of hydrogen that is much safer and cheaper than existing solutions. The researchers are using a well-known technology and the fourth most abundant element on Earth: iron.<h2>Chemical storage</h2>To store hydrogen better, Stark and his team are relying on the steam-iron process, which has been understood since the 19th century. If there is a surplus of solar power available in the summer months, it can be used to split water to produce hydrogen. This hydrogen is then fed into a stainless steel reactor filled with natural iron ore at 400 degrees Celsius. There, the hydrogen extracts the oxygen from the iron ore – which in chemical terms is simply iron oxide – resulting in elemental iron and water.“This chemical process is similar to charging a battery. &nbsp;It means that the energy in the hydrogen can be stored as iron and water for long periods with almost no losses,” Stark says. When the energy is needed again in winter, the researchers reverse the process: they feed hot steam into the reactor to turn the iron and water back into iron oxide and hydrogen. The hydrogen can then be converted into electricity or heat in a gas turbine or fuel cell. To keep the energy required for the discharging process to a minimum, the steam is generated using waste heat from the discharging reaction.<a target="_blank"></a><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725320890968-image.imageformat.1286.408338324.png" style="width: 100%px;" class="fr-fic fr-dib">The charging and discharging process for the storage technology. (Visualisations: ETH Zurich)<h2 id="isPasted">Cheap iron ore meets expensive hydrogen</h2>“The big advantage of this technology is that the raw material, iron ore, is easy to procure in large quantities. Plus it doesn’t even need processing before we put it in the reactor,” Stark says. Moreover, the researchers assume that large iron ore storage facilities could be built worldwide without substantially influencing the global market price of iron.The reactor in which the reaction takes place doesn’t have to fulfil any special safety requirements either. It consists of stainless steel walls just 6 millimetres thick. The reaction takes place at normal pressure and the storage capacity increases with each cycle. Once filled with iron oxide, the reactor can be reused for any number of storage cycles without having to replace its contents. Another advantage of the technology is that the researchers can easily expand the storage capacity. It’s simply a case of building bigger reactors and filling them with more iron ore. All these advantages make this storage technology an estimated ten times cheaper than existing methods.However, there’s also a downside to using hydrogen: its production and conversion are inefficient compared to other sources of energy, as up to 60 percent of its energy is lost in the process. This means that as a storage medium, hydrogen is most attractive when sufficient wind or solar power is available and other options are off the table. That is especially the case with industrial processes that can’t be electrified.<h2>Pilot plant on the Hönggerberg campus</h2>The researchers have demonstrated the technical feasibility of their storage technology using a pilot plant on the Hönggerberg campus. This consists of three stainless steel reactors with a capacity of 1.4 cubic metres, each of which the researchers have filled with 2–3 tonnes of untreated iron ore available on the market.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725320913294-image.imageformat.1286.858633795.jpg" style="width: 100%px;" class="fr-fic fr-dib">This 1.4-cubic-metre stainless steel reactor at the Hönggerberg campus holds 2–3 tonnes of untreated iron ore. (Image: ETH Zurich)“The pilot plant can store around 10 megawatt hours of hydrogen over long periods. Depending on how you convert the hydrogen into electricity, that’ll give you somewhere between 4 and 6 megawatt hours of power,” explains Samuel Heiniger, a doctoral student in Stark’s research group. This corresponds to the electricity demand from three to five Swiss single-family homes in the winter months. At present, the system is still running on electricity from the grid and not on the solar power generated on the Hönggerberg campus.This is soon set to change: the researchers want to expand the system such that by 2026, the ETH Hönggerberg campus can meet one-fifth of its winter electricity requirements using its own solar power from the summer. This would require reactors with a volume of 2,000 cubic metres, which could store around 4 gigawatt hours (GWh) of green hydrogen. Once converted into electricity, the stored hydrogen would supply around 2 GWh of power. “This plant could replace a small reservoir in the Alps as a seasonal energy storage facility. To put that in perspective, it equates to around one-tenth of the capacity of the Nant de Drance pumped storage power plant,” Stark says. In addition, the discharging process would generate 2 GWh of heat, which the researchers want to integrate into the campus’s heating system.<h2 id="isPasted">Good scalability</h2>But could this technology be harnessed to provide seasonal energy storage for Switzerland as a whole? The researchers have made some initial calculations: providing Switzerland with around 10 terawatt hours (TWh) of electricity from seasonal hydrogen storage systems every year in the future – which would admittedly be a lot – would require some 15–20 TWh of green hydrogen and roughly 10,000,000 cubic metres of iron ore. “That’s about 2 percent of what Australia, the largest producer of iron ore, mines every year,” Stark says. By way of comparison, in its <a target="_blank">Energy Perspectives 2050+</a>, the Swiss Federal Office of Energy anticipates total electricity consumption of around 84 TWh in 2050.If reactors were built that could store around 1 GWh of electricity each, they would have a volume of roughly 1,000 cubic metres. This calls for around 100 square metres of building land. Switzerland would have to build some 10,000 of these storage systems to obtain 10 TWh of electricity in winter, which corresponds to an area of around 1 square metre per inhabitant.<hr><h2 id="isPasted">Coalition for Green Energy and Storage (CGES)</h2>This project is part of the <a href="https://ethz.ch/en/news-and-events/eth-news/news/2023/06/eth-zurich-and-epfl-launch-a-green-energy-coalition.html" target="_blank">Coalition for Green Energy and Storage</a>, which ETH Zurich launched in 2023 together with EPFL, PSI and Empa and is driving forward together with industrial partners - including major Swiss energy suppliers and authorities. The coalition has set itself the goal of rapidly bringing innovative technologies for the production and storage of carbon-neutral gases and fuels and for CO2 capture to market maturity. As part of CGES, larger pilot plants (‘catapults’) are to be built to test these technologies and make important contributions to the climate-neutral transformation of the energy system and security of supply. The next step will be to establish an association that will network interested stakeholders, provide them with scientific support and guidance and facilitate the implementation of projects.<h2 id="isPasted">Reference</h2>Literature: Heiniger, SP; Fan Z; Lustenberger UB, Stark WJ: Safe seasonal energy and hydrogen storage in a 1 : 10 single-household-sized pilot reactor based on the steam-iron process. Sustainable Energy &amp; Fuels 2024, 8 (1), 125-132. <a href="https://doi.org/10.1039/D3SE01228J" target="_blank">https://doi.org/10.1039/D3SE01228J</a>

Researchers at ETH Zurich are using iron to store hydrogen safely and for long periods. In the future, this technology could be used for seasonal energy storage.

Iron as an inexpensive storage medium for hydrogen

The effective utilization of renewable energies such as solar and wind power is an essential element to achieve carbon neutrality. According to the <a href="https://kpmg.com/xx/en/home/insights/2023/06/statistical-review-of-world-energy-2023.html" target="_blank">Statistical Review of World Energy 2023</a> report published by the Energy Institute in the U.K., renewable energies including hydropower already account for approximately 30% of the world's power supplies. The total amount of that renewable energy is 8,539 TWh. This means it has grown more than four times the 2,058 TWh that it was in 1985.When it comes to ways to fully utilize renewable energy, many people may think of large-scale power generation in places brimming with natural energy. Examples of that include solar power generation in vast places like deserts or grasslands and wind power generation on the sea. However, there are forms of renewable energy even in the middle of any big city. In fact, efforts are being proactively promoted to introduce power generation with renewable energy in urban areas. In Japan, for instance, solar panels are being installed on the rooftops of buildings and the roofs of houses. The amount of power these solar panels generate is small. This means they are being positioned as auxiliary power supplies. Nevertheless, they are being effectively utilized. Moreover, new efforts are underway to also develop and introduce solar power generation technologies on the walls and in the windows of buildings and technologies that generate power using the vibrations that come from people walking.Looking at the situation from a global perspective, many small and medium-sized cities are striving to achieve local production for local consumption in which the power consumed locally is supplied by utilizing wind power, solar power, hydropower, and other forms of renewable energy in that locality. Furthermore, an increasing number of companies are also participating in RE100. RE100 is an international initiative the aim of which is for companies to supply the power they use in their businesses with 100% renewable energy. These companies are proactively introducing power generation equipment into their factories and other facilities to generate as much power as possible on their own (Fig. 1).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725259865043-microgrid-img0001.jpg" style="width: 100%px;" class="fr-fic fr-dib">Fig. 1: An increasing number of companies are participating in RE100 and promoting power generation on their own with renewable energy (Left: Kanazu Murata Manufacturing Clean Energy Park / Right: Carport solar panels capable of dealing with fallen snow)<h2 id="isPasted">Microgrids: Supporting the Local Production for Local Consumption of Renewable Energy</h2>We can call efforts to achieve local production for local consumption by converting renewable energy into power an extremely effective means of utilizing energy. This is because it is possible to minimize the power loss that always occurs in power systems during the transmission and distribution of that power.Large-scale power plants are located far from cities where a large amount of power is consumed in current power systems. The power generated in those power plants is transmitted and distributed to the areas where it is consumed to be utilized in daily life and socio-economic activities. However, approximately 30% of the power generated in the power plants is wastefully lost in the process up to its use via the power transmission and distribution network (also known as the grid). This is because a large amount of power is dissipated as heat or electromagnetic waves due to power lines and power converter loads. The shorter the distance of power transmission and distribution, the fewer times the power is converted, making it possible to reduce power loss. Therefore, we can minimize the occurrence of power loss by achieving local production for local consumption using the natural energy all around us as a distributed power supply.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725259887421-microgrid-img0002_en.jpg" style="width: 100%px;" class="fr-fic fr-dib">Fig. 2: Microgrid configuration and method of usage during normal times and emergenciesSource: <a href="https://www.meti.go.jp/shingikai/energy_environment/energy_resource/pdf/015_s01_00.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Materials from the Ministry of Economy, Trade and Industry's (a Japanese administrative agency) 4th Information Liaison Committee on the Introduction of Sustainable Renewable Energy in Local Communities</a>*This linked page is in Japanese.A small-scale power network aiming to achieve local production for local consumption of power is called a microgrid (Fig. 2). In addition to effectively utilizing renewable energy, microgrids have other benefits, as they are distributed power systems. For example, microgrids are capable of stably supplying power to communities even in the event of a large-scale power outage during an emergency such as a disaster. This allows us to maintain our daily life and business activities.<h2>Major Prerequisite of Operating Power Systems: Balancing Principle</h2>The concept of microgrids is simple. However, realizing microgrids is not that easy. This is because there is a major principle to the building and operating of power systems called the "balancing principle."The balancing principle is the rule that the amount of power supplied from a power plant must always match the amount of demand for power no matter what the power system. If we operate a power system in violation of this principle, the voltage of the power will become unstable and the equipment may fail, leading to a large-scale power outage.However, power derived from renewable energy like solar power is produced from unstable natural phenomena. Accordingly, we cannot conveniently adjust the amount of power generated. Therefore, it is difficult to supply the power we use and to fully use it with only power generated in the community. This means it is necessary to employ a mechanism that accommodates for surpluses and deficiencies with advanced operation and management like the fine adjustment of the balance in supply and demand in the community or the utilization of a large energy storage system (ESS).<h2>Smart Grids: Major Prerequisite for the Realization of Microgrids</h2>The means to solving this issue is a very similar concept to the microgrid called a "smart grid." A smart grid is a mechanism that automatically controls the necessary power so it can be supplied without surpluses or deficiencies by utilizing smart meters and other telecommunications devices to visualize in real time power demand in each individual household, business establishment, or other facility.Microgrids and smart grids are different concepts. Nevertheless, it is difficult to realize a microgrid that achieves local production for local consumption of power efficiently and effectively without introducing a smart grid mechanism. Smart grids grasp in real time and in detail the amount of power generated in distributed renewable energy power generation facilities and the amount of power consumed in daily life and business to achieve a balance between both while managing the charging and discharging of multiple distributed ESSs. If there is a deficiency in the power generated with just the charging and discharging permissible values of the installed ESSs, smart grids procure and release power from the wider grid to preserve the balance.The technology that uses IoT technology to control the amount of power supplied as if the multiple pieces of power generation equipment and ESSs in a microgrid were one power plant is called a "virtual power plant (VPP)." Meanwhile, smart meters are used to grasp in real time the power consumption situation in households and business establishments. Looking at the situation globally, smart meters are rapidly spreading. Smart meters began to be installed in households in 2014 in the greater Tokyo Metropolitan area in Japan. Installation was completed in almost all households and business establishments by the end of FY2020. The installation of smart meters across Japan is scheduled to be completed by the end of FY2024. In other words, we can say that the groundwork to promote the building of microgrids is steadily being laid.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725259914808-microgrid-img0003.jpg" style="width: 100%px;" class="fr-fic fr-dib">Fig. 3: The spread of smart meters is a major prerequisite to smart grids and microgrids<h2 id="isPasted">DC Power Transmission and Distribution Systems Aiming for Further Improvements in Efficiency</h2>Attempts are also being advanced to further raise the energy utilization rate with microgrids. Currently, technological development is underway to introduce a new power transmission and distribution network called a "DC microgrid." This DC microgrid will transmit and distribute DC power instead of the AC power used for commercial power supplies.DC power supplies such as solar batteries and storage batteries are often used on the power supply side of microgrids. On the other hand, looking at the power consumption side, telecommunications devices made using semiconductors and electronic components and energy-saving electronic goods made using inverters operate on DC power. This means both sides handle DC power.Currently, however, AC power is being transmitted and distributed, so it is necessary to convert the power both when it is transmitted and when it is used. Power loss occurs at that time. DC microgrids are a technology aiming to minimize this waste. It is envisioned that DC buses of about 400 V will be laid in place of conventional AC 200 V / 100 V power lines and that high-voltage commercial grids will operate by being connected via a bidirectional AC/DC converter. In addition to microgrids, DC power transmission systems are being used to transmit power over long distances. There are already examples of this technology being put to practical use in Europe and America.The building and operation of microgrids will no doubt progress at the same time as there is an expansion in the usage settings of renewable energy. It is expected that demand will further increase for even more highly efficient and flexible microgrids that can handle various usage settings and the electronic components that support the building of those microgrids.<hr><h2 id="isPasted">Other Links</h2><ul><li><a href="https://corporate.murata.com/en-eu/csr/environment_murata/climate_change?intcid1=mar_art_xxx_tao_xxx_tao-link" target="_blank">Reinforcement of climate change countermeasures</a></li><li><a href="https://www.murata.com/en-eu/apps/industry/smartgrid/smartmeter?intcid1=mar_art_xxx_tao_xxx_tao-link" target="_blank">"Smart meter" application guide</a></li></ul>

Supporting the Transition away from Fossil Fuels with the Power of Electronic Components

Microgrids: Promoting Local Production for Local Consumption of Renewable Energy

Rotor and Stator Detail of Electric DC Motor

This article delves into the intricacies of DC motor operation, exploring the key components, core mechanisms, types, and their interactions to produce rotational motion.

How Does a DC Motor Work? Unveiling the Power Behind Electric Motion

CMOS and CCD sensors both convert light into electronic signals, with CMOS using pixel-level transistors for faster, energy-efficient processing, while CCD transfers charge across the chip for superior image quality but with slower speed and higher power consumption.

CCD vs CMOS Image Sensors: A Comprehensive Guide for Engineering Professionals

Traditional mechanical flow sensors, which rely on moving parts, face significant challenges in harsh environments, such as wear and tear, fluid contamination, and pressure drops. These issues lead to inefficiencies and costly maintenance and are exacerbated in applications where precision and durability are paramount, such as water heaters, purifiers, industrial coolant systems, and water management.To address these challenges, <a href="https://www.sciosense.com/about/" target="_blank">ScioSense</a> has developed the UFM-01 Ultrasonic Flow Sensing Module. The UFM-01 leverages advanced ultrasonic technology to provide highly accurate and contactless flow measurements, eliminating the drawbacks of mechanical sensors. The UFM-01 stands out for its contactless measurement capabilities because of no moving parts, which ensures long-term reliability by eliminating the wear and tear associated with traditional mechanical flow sensors.The UFM-01 is engineered to deliver precise flow measurements across a wide range of applications. Its design is centered around ease of integration, making it an ideal choice for engineers seeking to enhance system performance.<h1 dir="ltr">Technological Advantages</h1>Traditional mechanical flow sensors that use turbine rotors or actuators often face significant challenges in fluid measurement as they rely on moving parts, which are prone to wear and tear, especially in abrasive or corrosive environments. This wear and tear leads to not only fluid contamination but also reduced accuracy over time, which necessitates constant maintenance and even replacements. Traditional mechanical flow sensors also introduce obstructions into the flow path, causing pressure drops in the system and reducing energy efficiency. Moreover, their performance is often affected by changes in fluid viscosity, temperature, and pressure, leading to inconsistent measurements.UFM-01 Ultrasonic Flow Sensing Module bypasses all these challenges by using sound waves to measure fluid velocity, eliminating the need for moving mechanical parts and thus increasing durability. Moreover, due to the non-intrusive nature of these ultrasonic sensors, they do not affect the liquids and are well suited for food applications.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI0MTM2MDI5MzM0LTE3MjQxMzYwMjkzMzQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="624" height="468" id="isPasted" class="fr-fic fr-dii">Figure 1: UFM-01 Ultrasonic Flow Sensing Module. Source: ScioSense.com<h1 dir="ltr">Technical Specifications of UFM-01</h1><h2 dir="ltr">Flow range</h2>A wide flow range is always crucial for any flow sensor as it ensures that the sensor can accommodate fluctuations in flow rates without compromising performance. The UFM-01 supports a wide flow range of 10 to 2000 liters per hour, making it suitable in both low and high-flow scenarios for a broad spectrum of applications. For example, in water distribution systems, the sensor can handle everything from small leaks to full-flow scenarios, which eliminates the requirement for multiple sensors to cover different flow ranges.<h2 dir="ltr">Accuracy</h2>Accuracy is also a critical aspect of flow measurement, especially in processes where precise control of fluid flow is necessary. In this regard, the UFM-01 offers an accuracy of ±5% for flow rates above 60 liters per hour, which ensures that the measurements are dependable even at higher flow rates. This level of accuracy is particularly important in applications like boilers, where incorrect flow &nbsp;measurements can lead to inefficiencies or even safety hazards.<h2 dir="ltr">Communication Interfaces</h2>The UFM-01 is equipped with a universal asynchronous receiver/transmitter (UART) protocol with 2400 bits per second baud rate and 8 data bit capacity, as well as single-wire communication&nbsp;<iframe id="66a22fbc1e6d3a7555231f98" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/sciosense-ufm-01-ultrasonic-flow-sensing-module?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp;&nbsp;</iframe> interfaces, which facilitate easy integration into a variety of systems. These interfaces allow the sensor to communicate seamlessly with microcontrollers, data loggers, or other digital systems, enabling real-time monitoring and control. Moreover, the ease of integration reduces development time and complexity, making the UFM-01 a convenient choice for both new designs and retrofit applications.<h2 dir="ltr">Power Requirements</h2>The UFM-01 operates at 5V with a low power consumption of just 2mA. This low power draw is beneficial in systems where energy efficiency is critical, such as in continuous monitoring applications or embedded systems where minimizing power consumption helps reduce overall system costs. The efficient power usage of the sensor module also ensures its reliability within power-constrained environments, contributing to the longevity and stability of the entire system without overloading power supplies.<h1 dir="ltr">Application Areas</h1>The versatility of the UFM-01 makes it suitable for a wide range of applications, as discussed here:<h2 dir="ltr">Water Management</h2>In water distribution and management systems, accurate flow measurement across a wide range is crucial for efficient resource utilization and conservation. The UFM-01 serves this exact purpose by allowing users to measure flow rates across a wide range. This precise measurement capability supports effective water management strategies, enabling operators to promptly identify inefficiencies and implement corrective actions.&nbsp;The UFM-01 helps both households and industries to conserve water, reduce waste, and optimize the distribution of this vital resource. For instance, the UFM-01 supports applications like smart faucets that dispense exact volumes of water for cooking and cleaning, as well as irrigation systems that deliver water based on real-time soil moisture levels. Similarly, in tankless water heaters, the sensor measurements are used to ensure that hot water is delivered only when needed, avoiding the energy waste of maintaining a hot water tank. In this way, the UFM-01 not only helps save water but also supports broader environmental goals by reducing energy consumption and lowering carbon footprints.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI0MTM2MDY2MzQ1LTE3MjQxMzYwNjYzNDUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="477" height="318" id="isPasted" class="fr-fic fr-dii">Figure 2: Kitchen setting with tap water Ultrasonic flow module. Source: ScioSense.com<h2 dir="ltr">Coolant Systems</h2>The UFM-01 is an ideal choice to monitor coolant flow in industrial processes. Coolant systems are critical for maintaining the proper temperature of machinery and processes, and any disruption in coolant flow can lead to overheating equipment damage or process inefficiencies. In this regard, UFM-01's dual capability of providing flow rate as well as temperature measurements provides users with a complete picture of coolant systems, allowing for real-time adjustments to maintain optimal thermal management and preventing costly downtime.<h2 dir="ltr">Food and Beverage Processing</h2>In food and beverage processing, maintaining cleanliness and safety is paramount. The UFM-01 is particularly suited for the food and beverage industry as it measures flow without direct contact with the fluid, eliminating the risk of contamination and providing a hygienic and non-intrusive environment. This feature is crucial in applications such as beverage dispensers, coffee machines, and other food-grade systems, where even minimal contamination can lead to significant quality and safety issues.<h1 dir="ltr">Benefits for Engineers</h1>The UFM-01 ultrasonic flow meter is developed to provide a multitude of benefits for engineers looking to simplify the design and deployment of flow-sensing solutions.<h2 dir="ltr">Ease of Integration&nbsp;</h2>UFM-01 is designed by prioritizing user-friendliness as it comes equipped with standard mechanical and communication interfaces to ensure seamless integration into existing systems. This sensing unit is equipped with a versatile 5-pin connector, a spool piece, and a serial communication module, making it adaptable to diverse application needs. A key feature that simplifies installation is the inclusion of a standard BSP ½" thread, which allows for simple and secure attachment to water lines. These standard interfaces and mounting options enable the UFM-01 to accelerate the development process, allowing engineers to bring products to market more swiftly and with fewer integration challenges.<h2 dir="ltr">Food-Grade Applications</h2>The UFM-01 is designed for use with food-grade material, making it ideal for applications involving consumable products. This feature is critical for industries such as food and beverage, pharmaceuticals, and biotechnology, where stringent safety and hygiene standards are imperative. Moreover, the sensor is engineered to function effectively in drinking and non-drinking-water systems, withstanding temperatures ranging from 1 to 60°C. Engineers can confidently deploy the UFM-01 in environments where product safety is paramount, knowing that it meets regulatory requirements and protects consumer health.<h2 dir="ltr">Enhanced Precision and Reliability</h2>The UFM-01 excels in delivering high accuracy and reliability in flow measurements. The advanced ultrasonic technology of UFM-01 provides precise readings, even in challenging environments. Moreover, since it is constructed with no moving, it offers an unlimited lifetime if operated in accordance with the specifications mentioned in the <a href="https://www.sciosense.com/wp-content/uploads/2024/07/UFM-01-Datasheet.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">datasheet.</a> For engineers, this reliability translates into lower operational costs and enhanced trust in the performance of their designs.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1724224203327-shutterstock_2200033193.jpeg" style="width: 832px;" class="fr-fic fr-dib">Figure 3. &nbsp;Pool maintenance using advanced sensors. Source: Shutterstock.<h2 dir="ltr">Maintenance</h2>Another huge benefit for engineers using UFM-01 is that its design eliminates the need for regular maintenance, providing a hassle-free solution for long-term operation. The risk of failure is significantly reduced due to the absence of moving parts, minimizing the likelihood of breakdowns. This also translates to a longer lifespan and high accuracy over time, lowering operational costs while ensuring reliable performance throughout the sensor's life.The Developers of UFM-01 Ultrasonic Flow Sensing Module The manufacturer behind UFM-01 technology is <a href="https://www.sciosense.com/about/" target="_blank">ScioSense</a>, a leading innovator in sensor technology dedicated to providing cutting-edge solutions that address the evolving needs of various industries. ScioSense has established itself as a trusted partner for engineers and developers seeking advanced sensing capabilities with a strong reputation for quality and reliability. Their team has 30 years of combined experience in the semiconductor industry, and their UFM-01 Ultrasonic Flow Sensing Module is a testament to their commitment to delivering exceptional products that enhance system performance and efficiency.<h1 dir="ltr">Call to Action</h1>UFM-01 Ultrasonic Flow Sensing Module is a great option for engineers looking for a reliable and efficient flow measurement sensor. Whether working on water management systems, control devices, or food processing equipment, the UFM-01 offers a reliable and accurate solution for flow measurement. To learn more, request a sample, or provide feedback on the module, visit ScioSense's <a href="https://www.sciosense.com/ufm-01-ultrasonic-flow-sensing-module/" target="_blank">website</a>. This is just the first iteration, and the company is keen for engineers to share their needs and ideas with them.<h1 dir="ltr">&nbsp;References</h1><ol><li dir="ltr">UFM-01 Ultrasonic Flow Sensing Module. ScioSense [Online], Available at: <a href="https://www.sciosense.com/ufm-01-ultrasonic-flow-sensing-module/" target="_blank">https://www.sciosense.com/ufm-01-ultrasonic-flow-sensing-module/</a></li><li dir="ltr">Check your flow to save water and energy. ScioSense [Online], Available at: <a href="https://www.sciosense.com/check-your-flow-to-save-water-and-energy/" target="_blank">https://www.sciosense.com/check-your-flow-to-save-water-and-energy/</a>&nbsp;</li></ol>

This article discusses how the ultrasonic flow sensing module provides precise, maintenance-free fluid measurement.

Advanced Flow Sensing: High Accuracy and Long Lifespan

In 2023, more than 100,000 Americans died from opioid overdoses. The most effective way to save someone who has overdosed is to administer a drug called naloxone, but a first responder or bystander can’t always reach the person who has overdosed in time.Researchers at MIT and Brigham and Women’s Hospital have developed a new device that they hope will help to eliminate those delays and potentially save the lives of people who overdose. The device, about the size of a stick of gum, can be implanted under the skin, where it monitors heart rate, breathing rate, and other vital signs. When it determines that an overdose has occurred, it rapidly pumps out a dose of naloxone.<iframe width="640" height="360" src="https://www.youtube.com/embed/_ZObB_mONE0?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>In a study&nbsp;<a href="https://doi.org/10.1016/j.device.2024.100517" target="_blank">appearing today in the journal&nbsp;Device</a>, the researchers showed that the device can successfully reverse overdoses in animals. With further development, the researchers envision that this approach could provide a new option for helping to prevent overdose deaths in high-risk populations, such as people who have already survived an overdose.“This could really address a significant unmet need in the population that suffers from substance abuse and opiate dependency to help mitigate overdoses, with the initial focus on the high-risk population,” says Giovanni Traverso,&nbsp;an associate professor of mechanical engineering at MIT, a gastroenterologist at Brigham and Women’s Hospital, and the senior author of the study.The paper’s lead authors are Hen-Wei Huang, a former MIT visiting scientist and currently an assistant professor of electrical and electronic engineering at Nanyang Technological University in Singapore; Peter Chai, an associate professor of emergency medicine physician at Brigham and Women’s Hospital; SeungHo Lee, a research scientist at MIT’s Koch Institute for Integrative Cancer Research; Tom Kerssemakers and Ali Imani, former master’s students at Brigham and Women’s Hospital; and Jack Chen, a doctoral student in mechanical engineering at MIT.<h2>An implantable device</h2>Naloxone is an opioid antagonist, meaning that it can bind to opioid receptors and block the effects of other opioids, including heroin and fentanyl. The drug, which is given by injection or as a nasal spray, can restore normal breathing within just a few minutes of being administered.However, many people are alone when they overdose, and may not receive assistance in time to save their lives. Additionally, with a new wave of synthetic, more potent opioids sweeping the U.S., opioid overdoses can be more rapid in onset and unpredictable. To try to overcome that, some researchers are developing wearable devices that could detect an overdose and administer naloxone, but none of those have yet proven successful. The MIT/BWH team set out to design an implantable device that would be less bulky, provide direct injection of naloxone into the subcutaneous tissue, and eliminate the need for the patient to remember to wear it.The device that the researchers came up with includes sensors that can detect heart rate, breathing rate, blood pressure, and oxygen saturation. In an animal study, the researchers used the sensors to measure all of these signals and determine exactly how they change during an overdose of fentanyl. This resulted in a unique algorithm that increases the sensitivity of the device to accurately detect opioid overdose and distinguish it from other conditions where breathing is decreased, such as sleep apnea.This study showed that fentanyl first leads to a drop in heart rate, followed quickly by a slowdown of breathing. By measuring how these signals changed, the researchers were able to calculate the point at which naloxone administration should be triggered.“The most challenging aspect of developing an engineering solution to prevent overdose mortality is simultaneously addressing patient adherence and willingness to adopt new technology, combating stigma, minimizing false positive detections, and ensuring the rapid delivery of antidotes,” says Huang. “Our proposed solution tackles these unmet needs by developing a miniaturized robotic implant equipped with multisensing modalities, continuous monitoring capabilities, on-board decision making, and an innovative micropumping mechanism.”The device also includes a small reservoir that can carry up to 10 milligrams of naloxone. When an overdose is detected, it triggers a pump that ejects the naloxone, which is released within about 10 seconds.In their animal studies, the researchers found that this drug administration could reverse the effects of an overdose 96 percent of the time.“We created a closed-loop system that can sense the onset of the opiate overdose and then release the antidote, and then you see that recovery,” Traverso says.<h2>Preventing overdoses</h2>The researchers envision that this technology could be used to help people who are at the highest risk of overdose, beginning with people who have had a previous overdose. They now plan to investigate how to make the device as user-friendly as possible, studying factors such as the optimal location for implantation.“A key pillar of addressing the opioid epidemic is providing naloxone to individuals at key moments of risk. Our vision for this device is for it to integrate into the cascade of harm-reduction strategies to efficiently and safely deliver naloxone, preventing death from opioid overdose and providing the opportunity to support individuals with opioid use disorder,” says Chai.The researchers hope to be able to test the device in humans within the next three to five years. They are now working on miniaturizing the device further and optimizing the on-board battery, which currently can provide power for about two weeks.

A new device, which can be implanted under the skin, rapidly releases naloxone to reverse an opioid overdose. Credit: Courtesy of the researchers, edited by MIT News

The new device, which can be implanted under the skin, rapidly releases naloxone when an overdose is detected.

An implantable sensor could reverse opioid overdoses

A tiny battery designed by MIT engineers could enable the deployment of cell-sized, autonomous robots for drug delivery within in the human body, as well as other applications such as locating leaks in gas pipelines.The new battery, which is 0.1 millimeters long and 0.002 millimeters&nbsp;thick — roughly the thickness of a human hair — can capture oxygen from air and use it to oxidize zinc, creating a current of up to 1 volt. That is enough to power a small circuit, sensor, or actuator, the researchers showed.“We think this is going to be very enabling for robotics,” says Michael Strano, the Carbon P. Dubbs Professor of Chemical Engineering at MIT and the senior author of the study. “We’re building robotic functions onto the battery and starting to put these components together into devices.”Ge Zhang PhD ’22 and Sungyun Yang, an MIT graduate student,&nbsp;are the lead author of the&nbsp;<a href="https://www.science.org/doi/10.1126/scirobotics.ade4642" target="_blank">paper</a>, which appears in&nbsp;Science Robotics.<h2>Powered by batteries</h2>For several years, Strano’s lab has been working on&nbsp;<a href="https://news.mit.edu/2018/cell-sized-robots-sense-their-environment-0723" target="_blank">tiny robots</a> that can sense and respond to stimuli in their environment. One of the major challenges in developing such tiny robots is making sure that they have enough power.Other researchers have shown that they can power microscale devices using solar power, but the limitation to that approach is that the robots must have a laser or another light source pointed at them at all times. Such devices are known as “marionettes” because they are controlled by an external power source. Putting a power source such as a battery inside these tiny devices could free them to roam much farther.“The marionette systems don’t really need a battery because they’re getting all the energy they need from outside,” Strano says. “But if you want a small robot to be able to get into spaces that you couldn’t access otherwise, it needs to have a greater level of autonomy. A battery is essential for something that’s not going to be tethered to the outside world.”To create robots that could become more autonomous, Strano’s lab decided to use a type of battery known as a zinc-air battery. These batteries, which have a longer lifespan than many other types of batteries due to their high energy density, are often used in hearing aids.The battery that they designed consists of a zinc electrode connected to a platinum electrode, embedded into a strip of a polymer called SU-8, which is commonly used for microelectronics. When these electrodes interact with oxygen molecules from the air, the zinc becomes oxidized and releases electrons that flow to the platinum electrode, creating a current.In this study, the researchers showed that this battery could provide enough energy to power an actuator — in this case, a robotic arm that can be raised and lowered. The battery could also power a memristor, an electrical component that can store memories of events by changing its electrical resistance, and a clock circuit, which allows robotic devices to keep track of time.The battery also provides enough power to run two different types of sensors that change their electrical resistance when they encounter chemicals in the environment. One of the sensors is made from atomically thin molybdenum disulfide and the other from carbon nanotubes.“We’re making the basic building blocks in order to build up functions at the cellular level,” Strano says.<h2>Robotic swarms</h2>In this study, the researchers used a wire to connect their battery to an external device, but in future work they plan to build robots in which the battery is incorporated into a device.“This is going to form the core of a lot of our robotic efforts,” Strano says. “You can build a robot around an energy source, sort of like you can build an electric car around the battery.”One of those efforts revolves around designing tiny robots that could be injected into the human body, where they could seek out a target site and then release a drug such as insulin. For use in the human body, the researchers envision that the devices would be made of biocompatible materials that would break apart once they were no longer needed.The researchers are also working on increasing the voltage of the battery, which may enable additional applications.

The zinc-air battery is 0.1 millimeters long and 0.02 millimeters thick. Credit: Courtesy of the researchers

These zinc-air batteries, smaller than a grain of sand, could help miniscule robots sense and respond to their environment.

Engineers design tiny batteries for powering cell-sized robots

Magnetic cores are essential in modern electronics, influencing the functionality and efficiency of devices, from power supplies to renewable energy systems. Traditional designs, especially those with a single large air gap, struggle to meet the high-frequency and efficiency demands of present-day applications.&nbsp;This challenge has catalyzed the development of distributed air gap cores, which are primarily used to increase power handling capabilities, enable higher currents, and enhance the efficiency and thermal performance of magnetics. Historically, the technology behind distributed air gap cores has been around for nearly 30 years but has always been an expensive, highly customized solution –that is, until now.&nbsp;Today, <a href="https://www.tdk-electronics.tdk.com/en/2796388/products/product-catalog/ferrites-and-accessories/cores-with-distributed-air-gaps" target="_blank" rel="noopener noreferrer">TDK Corporation</a>, a global leader in electronic components, is innovating the standardization of Distributed air gap cores in a way that is revolutionizing how the market will specify, purchase, and adopt these crucial components. This article explores how distributed air gap cores are revolutionizing magnetic core design, offering a glimpse into their principles, advantages, and standardization efforts led by TDK.<h2 dir="ltr" id="isPasted">Challenges of Traditional Single Large Air Gap Cores</h2>Traditional magnetic cores with single large air gaps exhibit a number of drawbacks due to their high magnetic reluctance. This reluctance acts as resistance to magnetization, leading to considerable energy losses as magnetic fields stray from their intended paths. The large fringing flux emitted from these air gaps spreads into the winding area, causing copper losses that further lead to a rise in temperature and proximity losses in high-frequency magnetics.These compounded inefficiencies escalate into several challenges, notably excessive heat that degrades component performance and shortens device lifespan—critical issues in high-power and high-frequency applications. Additionally, the need to mitigate these effects results in larger, heavier cores, posing significant limitations in applications requiring compactness and device miniaturization.<h2 dir="ltr">Development of Distributed Air Gap Cores</h2>Distributed air gap cores are a type of magnetic core, which feature a magnetic material interspersed with non-magnetic gaps. These gaps are distributed uniformly throughout the material, rather than being concentrated in one area. By integrating multiple smaller air gaps throughout the core, distributed air gap technology optimizes the magnetic flux path, significantly reducing areas prone to flux leakage and fringing effects. This strategic distribution of air gaps minimizes non-functional magnetic fields and enhances the core's overall efficiency and performance.Additionally, this configuration allows for a more compact core design without sacrificing power handling capabilities, thus supporting the trend towards miniaturization in technology. The benefit extends to improved thermal management, as the reduced energy losses lead to less heat generation, allowing devices to operate at higher frequencies without compromising their longevity or performance.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNTQ4MzA2NDk5LWltYWdlMy5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="thermal-image-temperature-comparision-single-air-ga-core-vs-distributed-air-gap-core">&nbsp;A thermal image comparison shows that after 60 minutes of operation at 3.4 A and 50 kHz, the temperature increase in a single large air gap core (left) is significantly higher than in a distributed air gap core (right).Here is a summary of the key benefits of using distributed air gap cores to address issues posed by their traditional counterparts:<ul><li dir="ltr">Improved Fringing Flux: Anywhere a gap is present, fringing flux is emitted. When there is a larger gap, there is also a larger fringing flux path. By incorporating a distributed air gap, the fringing flux losses decrease as the number of smaller air gaps increases. This can reduce the fringing flux losses by up to 70%.&nbsp;</li><li dir="ltr">Increased Power Density and Optimized Efficiency: Distributed air gaps increase the power handling capability of the design. In many cases the winding area is reduced to avoid fringing flux losses. By using distributed gapped cores to minimize the fringing flux, the full winding area can be used. This can allow for either a smaller component or higher power through the originally selected component.</li><li dir="ltr">Enhanced Performance: In high-frequency applications, the skin effect and proximity effect can lead to significant losses in electrical conductors. The skin effect refers to the tendency of alternating current (AC) to distribute itself within a conductor such that the current density is highest near the surface, effectively reducing the cross-sectional area available for current flow. The proximity effect, on the other hand, occurs when alternating magnetic fields from neighboring conductors cause the current to concentrate in certain regions of a conductor, increasing resistance and associated losses.&nbsp; Litz wire is a specialized type of wire designed to mitigate these effects. It consists of multiple thin, insulated strands woven together in a specific pattern, which helps reduce the losses caused by the skin and proximity effects. However, when using distributed air gap cores, which reduce the effects of fringing flux, it is possible to use solid wire instead of Litz wire. This substitution could lead to higher copper utilization within the winding area, thereby increasing efficiency and reducing costs.</li><li dir="ltr">Utilization of New Semiconductor Material: Distributed air gap cores are well-suited for applications using higher frequency switching technologies like Silicon Carbide and Gallium Nitrides. Their design reduces energy losses and enhances thermal management, making them ideal for handling the increased power densities and rapid switching speeds these technologies require.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1723548324218-image2.gif" style="width: 100%px;" class="fr-fic fr-dib" alt="hot-spot-comparision-single-gap-vs-distributed-gap-core">Hot spot comparison for single large air gap vs. distributed air gap cores: distributed air gaps reduce fringing flux and hotspots, improving thermal performance and efficiencyDistributed air gap cores have seen significant innovation in recent years. However, these solutions have been tailored and delivered specifically for the design of each end application.&nbsp;An unfortunate side effect of this is that each time a core is created for a custom application, it likely will not be used again for another design, increasing the overall cost of the technology and preventing new innovations from being passed on to others.<h2 dir="ltr">Introducing TDK’s Standardized Solutions</h2>TDK has responded to the need for taking a highly customized technology like the distributed air gap core and <a href="https://www.tdk-electronics.tdk.com/en/2796388/products/product-catalog/ferrites-and-accessories/cores-with-distributed-air-gaps" target="_blank" rel="noopener noreferrer">providing a more standardized solution for it</a>. A standardized distributed air gap core portfolio offer reduces the dependence on custom-built offerings and will revolutionize the Distributed air gap core industry. Such standardized solutions will speed up time to market, improve the return on investment, and stimulate innovation while still allowing for application-specific customization.<iframe width="640" height="360" src="https://www.youtube.com/embed/5KzHH0Mh3bY?&amp;ab_channel=TDK&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;</iframe>TDK solutions also offer one of the best total costs of ownership and cost/performance ratios due to reliability and reduced proximity losses. This becomes apparent when a single large air gap core is compared to various configurations of distributed air gaps.&nbsp;In fact, the best cost/performance ratio is achieved with three identical air gaps. Thermal image test comparisons between a single large air gap, when contrasted against three identical distributed air gap core sets, clearly show significantly lower outputs at varied frequencies.&nbsp;<h2 dir="ltr">The TDK Standardization Revolution</h2>As a pioneer in magnetics, TDK is the first to offer standard distributed air gap core solutions. TDK continues to invest in the future of magnetics and to support this introduction. The company has invested heavily in new automated manufacturing processes and equipment that improve the quality of air-gapped core products.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNTQ4MzQwMzcwLWltYWdlNC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="distribute-air-gap-ferrite-core-by-TDK-corporation">A standard ferrite core with distributed air gaps by TDK. Image Source: TDK Corporation[1]TDK is revolutionizing how the market will specify, purchase, and adopt distributed air gapped cores with new standardized products. TDK offers the market easy access to a once highly customized solution. Manufacturing innovation is allowing the industry to take advantage of the technology in new ways. Additional innovation will follow, just as it does whenever a custom solution is standardized.Visit the <a href="https://www.tdk-electronics.tdk.com/en/2796388/products/product-catalog/ferrites-and-accessories/cores-with-distributed-air-gaps" target="_blank" rel="noopener noreferrer">TDK Corporation’s official website</a> to learn more about their innovative distributed air gap cores and how they can enhance the efficiency and performance of your high-power high-frequency applications.<h2 dir="ltr">Conclusion</h2>The development and standardization of distributed air gap cores mark a major advancement in magnetic materials used in electrical/electronics applications. By addressing the challenges with traditional designs, distributed air gap cores enhance efficiency, thermal management, and power handling.&nbsp;TDK’s leadership in standardizing these cores has reduced costs and accelerated innovation across various industries. As applications in industries, renewable energy, automotive, and high-frequency electronics grow, the importance of distributed air gap cores will continue to rise.<h2 dir="ltr">References</h2>[1] TDK Electronics. Distributed air gaps in ferrite cores. Available from: <a href="https://www.tdk-electronics.tdk.com/en/180386/tech-library/publications/ferrites/ferrites-air-gaps-standard/2905788" target="_blank">https://www.tdk-electronics.tdk.com/en/180386/tech-library/publications/ferrites/ferrites-air-gaps-standard/2905788</a>

Distributed air gap cores, traditionally expensive, enhance efficiency and thermal management in high-power, high-frequency applications by reducing reluctance and fringing flux. Standardization efforts by brands like TDK are making these advanced solutions more accessible and cost-effective.

Distributed Air Gap Cores: Standardizing High-Performance Magnetic Solutions

<h1 dir="ltr" id="isPasted">Introduction</h1>Magnetic current sensors are revolutionizing PCB design by offering simpler solutions to traditional current measurement methods. These sensors integrate multiple components into a single IC to reduce design complexity and enhance overall system performance.This article explores how magnetic current sensors address complexity issues in PCB design, focuses on their advantages over conventional methods and provides insights through a detailed case study.In our <a href="https://www.wevolver.com/article/next-generation-current-measurement-addressing-pcb-design-challenges-with-magnetic-current-sensors/draft" target="_blank">Next-Generation Current Measurement series</a>, we've previously explored various challenges associated with traditional current sensing methods. This article focuses specifically on addressing the challenge of complexity within PCB design and highlights the advantages of magnetic current sensors in modern electronics.<h1 dir="ltr">Complexity Challenges in Traditional Current Sensing Methods</h1>Traditional current sensing methods, as previously highlighted in this series, present a range of challenges that significantly complicate the design and functionality of PCBs. These methods typically rely on shunt resistors (along with additional components), which are prone to generating substantial heat, necessitating more complex thermal management systems than non-shunt solutions. As a result, traditional methods end up consuming valuable PCB space with additional components like heat sinks.Beyond the issues of space and heat, shunt resistors introduce electrical and design complexities. They inherently possess inductance, which leads to voltage spikes when there is a rapid change in current. This behavior can disrupt other sensitive components and skew the measurement accuracy, which presents a significant challenge in maintaining the integrity and reliability of the system. Additionally, the impedance of a shunt resistor increases with frequency due to this inductance, thereby resulting in notable sensitivity changes at higher frequencies.For example, a high-end shunt resistor with a 200 µΩ resistance and 3nH inductance, which can cost more than $0.15 and occupy over 50 mm² space on the PCB, suffers from performance degradation at bandwidths exceeding 10 kHz. The inductance impacts the shunt's operation by affecting its performance at high frequencies and necessitates the integration of additional components to mitigate the resultant issues.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI0MzExMzEwODYxLTI0MDgyMF9KZXNzLTAxLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">The frequency response of a shunt resistor with a 200 µΩ resistance and 3nH inductance demonstrates how the shunt impedance increases drastically with frequency.<h2 dir="ltr">Mitigation Strategies in Conventional Systems</h2>To address these voltage spikes and other inductive effects, traditional systems often require external components to filter the shunt voltage. This process adds to the design complexity as it involves the careful tuning of filter components based on the system's specific requirements to ensure the amplifier's input stage is protected from saturation during high transient switching events.The design of these filters makes it necessary to use precision components to maintain its performance parameters like a high common-mode rejection ratio and pole location, which involve the use of low-value resistors to minimize effects due to input bias currents and also high-precision capacitors and resistors. These components can be large and costly, which further complicates the PCB design and addis to the overall system cost. Achieving an accuracy of less than 1% over various frequencies typically requires specialized tuning, including trial and error, which is both time-consuming and expensive.<h2 dir="ltr">Impact of Complexity on Solution Cost</h2>The complexities involved in traditional current sensing methods escalate the overall solution cost. The necessity for precision components, extensive protective measures against electrical noise and spikes, and the labor-intensive design process not only increases the direct materials and manufacturing costs but also extends development cycles. This increased expenditure can affect the profitability and market competitiveness of products, particularly in industries where rapid innovation and cost efficiency are critical.&nbsp;<h1 dir="ltr">Minimizing PCB Design Complexity with Magnetic Current Sensing</h1>Magnetic current sensors represent a significant advancement in current sensing and offer a comprehensive solution that integrates multiple functions into a single component. This integration streamlines the design process and minimizes the space requirements.<h2 dir="ltr">Streamlined Design Process</h2>Magnetic current sensors incorporate integrated signal conditioning, which eliminates the need for additional filtering and complex components. This simplifies the PCB layout by reducing the number of components and enhances the overall system reliability by minimizing potential failure points. The factory calibration of these sensors ensures consistent performance across diverse temperatures and operational conditions to alleviate the need for extensive calibration by the end-user. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNDcyNzY3MDk1LWV5SmlkV05yWlhRaU9pSjNaWFp2YkhabGNpMXdjbTlxWldOMExXbHRZV2RsY3lJc0ltdGxlU0k2SW1aeWIyRnNZUzh4TnpJek1UTXpNRE14T0Rjd0xUSTBNRGN5TVY5S1pYTnpMVEF5TG1wd1p5SXNJbVZrYVhSeklqcDdJbkpsYzJsNlpTSTZleUozYVdSMGFDSTZPVFV3TENKbWFYUWlPaUpqYjNabGNpSjlmWDAuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii" alt="allegro-magnetic-current-sensor">Traditional current sensing methods typically involve a complex assembly of 5-9 components, including resistors, capacitors and operational amplifiers, whereas magnetic current sensors consolidate all necessary functions into a single unit to simplify the design.<h2 dir="ltr">Enhanced Measurement Accuracy</h2>Unlike traditional shunt systems that require high levels of amplification for low-resistance measurements—often introducing noise and potential errors—magnetic current sensors maintain accuracy and reliability without the need for such amplifications. These sensors come factory-calibrated to ensure consistent performance across a broad temperature range and to enhance their reliability. This inherent stability makes them effective in environments where interference or noise could compromise the system’s functionality and provide a dependable solution even under variable operating conditions.<h2 dir="ltr">Economic Advantages</h2>Magnetic current sensors reduce the number of components required on the PCB, thereby lowering material costs and simplifying assembly. This decrease in component count can lead to fewer manufacturing errors and less rework to ultimately reduce overall production costs. Additionally, the diminished need for specialized components and extensive laboratory testing can further lower development expenses to make the design-to-production process more economically efficient.<h2 dir="ltr">Flexibility in Applications</h2>The versatility of magnetic current sensors allows for their use in various configurations, such as low-side, high-side, and in-line applications. Moreover, these sensors can handle extensive voltage ranges making them suitable for a broad spectrum of industrial applications.This integration streamlines design and manufacturing processes, and opens new avenues for innovation in PCB design, enabling engineers to focus more on enhancing functionality rather than navigating technical hurdles.<h2 dir="ltr">Accelerated Development and Deployment</h2>The simplified design enabled by magnetic current sensors can significantly expedite the product development process. With fewer components to integrate and test, the timeline from concept to market-ready product can be shortened. In rapidly evolving industries, this faster time-to-market is invaluable and provides a substantial competitive edge by enabling quicker responses to market demands and technological advancements.<h1 dir="ltr">Case Study: Clean Energy Solar &amp; Storage System Manufacturer</h1>A prominent example of the benefits of magnetic current sensors can be seen in a case study involving a clean energy solar and storage system manufacturer in the United States. This company faced considerable challenges with the complexity of traditional shunt resistors for current sensing across multiple points in their systems. Each additional sensing point introduced complexity due to the need for accurate filter design and variability management of passive components over temperature and lifespan.<h2 dir="ltr">Challenge Faced</h2>The manufacturer required a current sensing solution that could be implemented efficiently within the tight size and performance constraints of their innovative solar and storage systems. Traditional methods were proving too cumbersome, time-consuming and prone to error, which impeded rapid development and scaling.<h2 dir="ltr">Solution Delivered</h2>After looking at various options, the brand decided to switch to <a href="https://www.allegromicro.com/en/products/sense/current-sensor-ics/zero-to-fifty-amp-integrated-conductor-sensor-ics/acs711?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-3&utm_content=landing-page" target="_blank">Allegro’s ACS711</a> magnetic current sensor. This sensor offered a drastically simplified installation process due to its integrated signal conditioning and factory calibration, which eliminated the need for additional filtering and on-site calibration.<h2 dir="ltr">Outcome Achieved</h2>The adoption of the ACS711 allowed the manufacturer to streamline their design considerably. This simplification reduced the overall design time and manufacturing costs, facilitated a faster transition from prototype to production and ultimately accelerated the time-to-market for their products. The flexibility of the ACS711 to be used in various applications also allowed the company to standardize their sensing approach across different parts of their system, thereby simplifying inventory and maintenance.<h1 dir="ltr">Overcoming Complexity Challenges in PCB Design with Magnetic Current Sensors by Allegro MicroSystems</h1>The ACS37041 and ACS37220 from <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-3&utm_content=landing-page" target="_blank">Allegro MicroSystems</a> exemplify the advancements in magnetic current sensing technology that significantly reduce design complexity while enhancing performance in modern electronics.<a href="https://www.allegromicro.com/en/products/sense/current-sensor-ics/zero-to-fifty-amp-integrated-conductor-sensor-ics/acs37041?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-3&utm_content=landing-page" target="_blank">Allegro ACS37041</a>: This sensor is housed in a compact SOT23-W package, ideal for space-constrained applications. It supports current measurement up to 30A and operates up to 100V(RMS), which makes it versatile for applications in power, manufacturing, automotive, and other sectors. Its low resistance of 1 mΩ and an error below ±5% across temperature variations ensure precise current measurement without the need for external calibration, thereby simplifying the design process.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNzExOTc3ODg5LTI0MDgxMV9KZXNzIDItMDMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib" alt="allegro-acs-37041">Allegro ACS37041 in a 5-pin SOT23–W package along with a typical application circuit<a href="https://www.allegromicro.com/en/products/sense/current-sensor-ics/fifty-to-two-hundred-amp-integrated-conductor-sensor-ics/acs37220?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-3&utm_content=landing-page" target="_blank">Allegro ACS37220</a>: Designed for high-current applications, the ACS37220 can handle up to 200A and also operates under 100V(RMS). It features ultra-low resistance of 100 μΩ and is AEC-Q100 certified, which is crucial for reliability in automotive environments. The sensor is encased in a 4 x 4 mm QFN package and optimal for applications that demand high performance in a minimal footprint.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNzExOTk5MDI0LTI0MDgxMV9KZXNzIDItMDIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib" alt="Allegro-acs-37220-magnetic-current-sensor">Allegro ACS37220 in a 7-pin QFN package along with a typical application circuitBoth sensors embody the integration of advanced signal conditioning features, which eliminate the need for additional filtering and ancillary components. This integration saves PCB space and reduces the potential for errors during the design phase, thus streamlining the development process and accelerating the time-to-market for new products.<h1 dir="ltr">Conclusion</h1>Magnetic current sensors have demonstrably overcome many of the complexities associated with traditional PCB design for current sensing. By reducing design complexity, enhancing reliability and cutting costs, these sensors support a more innovative approach to electronics design.&nbsp;This article concludes our Next-Generation Current Sensing series. Throughout this series, we explored how magnetic current sensors, particularly those developed by <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-3&utm_content=landing-page" target="_blank">Allegro MicroSystems</a>, revolutionize PCB design by addressing size, heat, and complexity challenges. The cutting-edge solutions by Allegro MicroSystems set new industry standards for current measurement.Visit <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-3&utm_content=landing-page" target="_blank">Allegro MicroSystem's official website</a>&nbsp;today to find the perfect solution for your current measurement needs.<hr>This article is a part of&nbsp;<a href="https://www.wevolver.com/article/next-generation-current-measurement-addressing-pcb-design-challenges-with-magnetic-current-sensors" target="_blank" rel="noopener noreferrer">Next-Generation Current Sensing</a>, a series that delves into cutting-edge developments in current measurement.&nbsp;Articles featured in the series:<ul><li dir="ltr"><a href="https://www.wevolver.com/article/next-generation-current-measurement-addressing-pcb-design-challenges-with-magnetic-current-sensors" target="_blank" rel="noopener noreferrer">Next-Generation Current Measurement: Addressing PCB Design Challenges with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-size-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Size Challenges in PCB Design with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-heating-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Heating Challenges in PCB Design with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-complexity-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Complexity Challenges in PCB Design with Magnetic Current Sensors</a></li></ul>

Article 3 of Next-Generation Current Measurement Series: Magnetic current sensors streamline PCB design by accurately measuring current through magnetic fields to reduce complexity in modern electronics.

Overcoming Complexity Challenges in PCB Design with Magnetic Current Sensors

<h1 dir="ltr" id="isPasted">Introduction</h1>In the ever-evolving world of electronic circuits, managing heat within printed circuit board (PCB) designs has become a pivotal challenge, especially as devices shrink and demands on performance increase. Traditional current sensing methods, particularly those involving shunt resistors, often lead to significant heat generation, which can impair system reliability and performance.&nbsp;Magnetic current sensors present an innovative solution to these challenges. By offering a way to measure currents with minimal heat production, these sensors help preserve the integrity of electronic systems. This article explores how magnetic current sensors can transform thermal management in PCB design, which marks a step forward in electronics manufacturing.In our <a href="https://www.wevolver.com/article/next-generation-current-measurement-addressing-pcb-design-challenges-with-magnetic-current-sensors/draft" target="_blank">Next-Generation Current Measurement series</a>, we previously explored various challenges associated with traditional current sensing methods. This article focuses specifically on addressing the thermal challenges within PCB design to highlight the advantages of magnetic current sensors in modern electronics.<h1 dir="ltr">Heat Challenges in Traditional Current Sensing Methods</h1>Traditional methods of current measurement often rely on shunt resistors, components known for generating significant amounts of heat during operation. This heat production is primarily due to the resistance inherent in shunt resistors, where power dissipation is calculated as:P=I2RAt high currents, even a low-resistance shunt resistor can dissipate considerable power, thereby raising the temperature of both the resistor and its surrounding components on the PCB.Excessive heat can lead to several adverse effects on electronic systems, such as:Component Degradation: Continuous high temperatures can accelerate the aging process of electronic components, which reduces their operational lifespan.System Reliability:&nbsp;Heat can cause electronic components to fail or operate unpredictably to lead to system instability and potential data loss.Thermal Runaway:&nbsp;In power-intensive applications, heat generation can lead to thermal runaway, where the system becomes unable to regulate its temperature, and causes further increases in heat and potential damage.These challenges necessitate complex heat mitigation strategies that often involve using additional components such as heat sinks and thermal pads or choosing shunt resistors with extremely low values, all of which increase the overall cost and complexity of the PCB design. Additionally, the physical space required for effective heat dissipation further limits the miniaturization of electronic devices, a critical factor in many modern applications.<h1 dir="ltr">Limitations of Conventional Heat Mitigation Strategies</h1>While conventional methods for thermal management can be effective, they come with notable drawbacks that can hinder the design and functionality of compact electronic devices:Increased System Cost and Complexity: Implementing heat sinks and thermal pads adds to the material costs and complicates the assembly process. This not only increases the overall production expenses but also extends the time required for manufacturing and assembly.Larger Board Requirements: To accommodate heat sinks and ensure adequate spacing for air circulation, PCBs often need to be designed with larger dimensions. This requirement runs counter to the trend towards miniaturization in the electronics industry, where reducing the size of devices is frequently a primary objective.Aesthetic and Practical Design Limitations: Larger heat sinks and expanded PCB areas can impinge on the design aesthetics and the practicality of electronic devices, especially in devices in which form factor is crucial.These traditional heat management approaches, while necessary for thermal control, impose significant limitations on the design and innovation potential of new electronic products.<h1 dir="ltr">Inadequacies of Low Resistance Shunt Resistors</h1>To minimize heat generation, some designs opt for exceptionally low resistance shunt resistors. However, this solution introduces its own set of challenges that can adversely affect the overall efficiency and performance of electronic systems:High-gain Amplifiers: Low resistance values typically require the use of high-gain amplifiers to produce a measurable output signal. This amplification can significantly increase the noise in the measurements, which compromises signal integrity and accuracy. High noise levels can be particularly problematic in precision applications, where the quality of data is important.Increased Component Size and Cost:&nbsp;Achieving extremely low resistance often necessitates using larger or more specialized shunt resistors, which can be more expensive. This not only impacts the cost-efficiency of the design but also counteracts efforts to reduce PCB space usage.Complexity in Design: Incorporating very low resistance shunt resistors and their associated high-gain amplifiers requires intricate design considerations. These include careful routing and shielding to prevent interference, as well as additional calibration steps during manufacturing to ensure accuracy. This complexity adds to the development time and costs, which increases the overall project timeline and budget.As engineers seek more streamlined and cost-effective solutions, the focus has shifted towards innovative technologies that inherently avoid these complications. Magnetic current sensors represent one such advancement and offer significant benefits in terms of heat management, design simplicity and cost-effectiveness.<h1 dir="ltr">Minimizing PCB Heating with Magnetic Current Sensing</h1>The adoption of magnetic current sensors presents a significant advancement in addressing the heat-related challenges of current sensing. These sensors utilize a Hall-effect-based methodology that inherently exhibits low resistance and minimal heat generation compared to traditional shunt resistors.<h2 dir="ltr">Comparison with Traditional Shunt Resistors</h2>Lower Resistance: Magnetic current sensors do not rely on resistance and Ohm’s law for measurement. However, magnetic current sensors have metal leadframes for their current carrying path which possess minimal resistance when compared to most shunt resistors used in current measurement circuits. Consequently, magnetic current sensors enable significantly lower system heating—essential for designing smaller or more efficient electronic devices.Simplified Signal Processing: The output of magnetic current sensors is directly proportional to the magnetic field and does not require the high levels of amplification needed for low-resistance shunt measurements. This reduces complexity and potential noise interference in signal processing.These features make magnetic current sensors an attractive alternative for modern electronics, where efficiency and miniaturization are key. By integrating functions traditionally handled by multiple components into a single, compact package, these sensors not only mitigate heat generation but also improve the overall performance and reliability of electronic systems with less potential points of failure. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNTM5OTA3NTIyLTI0MDcyMV9KZXNzLTA1LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="power-dissipation-shunt-resistor-vs-magnetic-current-sensors">Power dissipation in shunt resistors vs. Allegro’s 4x4mm QFN “EZ” package. Image source: Allegro MicroSystems<h1 dir="ltr">Key Benefits of Magnetic Current Sensors</h1>Magnetic current sensors like those from <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-2&utm_content=landing-page" target="_blank">Allegro MicroSystems</a> significantly enhance PCB designs by providing essential advantages over traditional sensing methods. These benefits are tailored to meet the evolving demands of advanced electronic systems.<h2 dir="ltr">Improved Thermal and Operational Performance</h2>Minimal Thermal Impact: Magnetic current sensors operate with significantly lower heat output, which eliminates the need for complex thermal management systems and results in a cleaner and more efficient design.Reliable Accuracy:&nbsp;These sensors maintain high measurement accuracy without the complications of thermal drift, which can negatively affect components subjected to high temperatures, to ensure dependable operation across various applications.<h2 dir="ltr">Enhanced Efficiency and Design Simplification</h2>Integrated Functionality:&nbsp;These sensors combine multiple sensing functions into a single device, thereby reducing the need for additional components and simplifying the overall design.Streamlined Manufacturing: The compact and integrated nature of magnetic sensors allows for a more straightforward assembly process to reduce both time and cost associated with manufacturing.<h2 dir="ltr">Cost and Space Optimization</h2>Reduced PCB Size:&nbsp;By eliminating the need for ancillary components like high-gain amplifiers and heat dissipation units, these sensors allow for more compact PCB layouts.Cost-Effective Material Use: Lower numbers of components and simplified circuit design translate into reduced material use and cost, thus making the overall product more economically viable.<h2 dir="ltr">Flexibility in Application</h2>Versatile Integration: The small footprint and robust performance of magnetic current sensors facilitate their integration into a diverse range of products, particularly suitable for medium to high current applications ranging from tens of amperes in industrial systems to larger scales.Enhanced Durability: With fewer parts and reduced susceptibility to heat degradation, these sensors offer greater durability, which is crucial for devices in harsh environments.<h1 dir="ltr">Case Study: European Motor Module Manufacturer</h1>An example of the practical benefits offered by magnetic current sensors can be seen in the experience of a leading European motor module manufacturer. This company faced significant challenges in designing compact motor modules that required minimal power dissipation to maintain low system temperatures. Traditional shunt resistors were inadequate due to their high-power dissipation and led to excessive heat generation, which impacted both performance and reliability.<h2 dir="ltr">Challenge Faced</h2>The manufacturer needed a current sensing solution that fit within the stringent size and thermal constraints of their compact motor designs. Traditional shunt resistors and their auxiliary components were too bulky and generated too much heat, which necessitates additional cooling mechanisms that increased both cost and complexity.<h2 dir="ltr">Solution Implemented</h2>The manufacturer explored alternative technologies and ultimately chose to integrate <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-2&utm_content=landing-page" target="_blank">Allegro</a>’s ACS37220 magnetic current sensor into their designs. This sensor stood out due to its low power dissipation and compact size.<h2 dir="ltr">The Outcome</h2>Incorporating the ACS37220 resulted in several significant improvements:<ul><li dir="ltr">Reduced Heat Generation: The lower resistance of the magnetic sensor minimized the amount of heat produced, which allowed the motor modules to operate within safe thermal limits without the need for extensive cooling strategies.</li><li dir="ltr">Compact Design: The small size of the ACS37220 enabled the manufacturer to meet the compact design specifications of their motor modules.</li><li dir="ltr">Cost and Complexity Reduction: By eliminating the need for additional thermal management components, the overall cost and design complexity were significantly reduced.</li></ul>This successful implementation of the ACS37220 met the manufacturer's specific needs and demonstrated the magnetic current sensor's potential to transform product design by overcoming traditional challenges associated with current sensing and thermal management.<h1 dir="ltr">Overcoming Heating Challenges in PCB Design with Magnetic Current Sensors by Allegro MicroSystems</h1>The <a href="https://www.allegromicro.com/en/products/sense/current-sensor-ics/fifty-to-two-hundred-amp-integrated-conductor-sensor-ics/acs37220?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-1&utm_content=landing-page" target="_blank">Allegro ACS37220</a> magnetic current sensor offers essential features to effectively mitigate heating issues in electronic systems. Capable of handling high currents up to 200A, it is particularly suitable for power-intensive applications, yet it operates with significantly reduced heat generation.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNTUxMjU3MjkxLTI0MDcyMV9KZXNzLTA2LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 832px;" class="fr-fic fr-dib" alt="allegro-acs-37220">ACS37220 Magnetic Current Sensor by Allegro Microsystems in a 7-pin 4 x 4 mm QFN packageIts compact 4x4 mm QFN package maximizes PCB space efficiency, which eliminates the need for additional cooling components such as heat sinks or fans. This benefit simplifies design and reduces overall manufacturing costs. These characteristics make the ACS37220 an optimal choice for ensuring thermal efficiency and enhancing the reliability of modern electronic systems where maintaining lower temperatures is crucial.<h1 dir="ltr">Conclusion</h1>This discussion highlights the significant role of magnetic current sensors in mitigating thermal challenges within PCB design. By drastically reducing heat generation compared to traditional shunt resistors, these sensors enhance system reliability and longevity. Their continued integration is vital for advancing thermal management in electronics to ensure that as devices become smaller, they remain efficient.Visit <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-2&utm_content=landing-page" target="_blank">Allegro Microsystems' official website</a> today to find the perfect solution for your current measurement needs.<hr>This article is a part of&nbsp;<a href="https://www.wevolver.com/article/next-generation-current-measurement-addressing-pcb-design-challenges-with-magnetic-current-sensors/draft" target="_blank" rel="noopener noreferrer">Next-Generation Current Sensing</a>, a series that delves into innovative developments in current measurement.&nbsp;Articles featured in the series:<ul><li dir="ltr"><a href="https://www.wevolver.com/article/next-generation-current-measurement-addressing-pcb-design-challenges-with-magnetic-current-sensors" target="_blank" rel="noopener noreferrer">Next-Generation Current Measurement: Addressing PCB Design Challenges with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-size-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Size Challenges in PCB Design with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-heating-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Heating Challenges in PCB Design with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-complexity-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Complexity Challenges in PCB Design with Magnetic Current Sensors</a></li></ul>

Article 2 of Next-Generation Current Measurement Series: Magnetic current sensors offer a streamlined and thermally-efficient solution to traditional current measurement methods, which significantly lowers heat production and reduces component size on PCBs, essential for compact electronic designs.

Overcoming Heating Challenges in PCB Design with Magnetic Current Sensors

As the demand for smaller electronic devices increases, engineers face significant challenges in integrating all necessary components within constrained PCB areas. One critical aspect of electronic design is current measurement, which is vital for monitoring and controlling energy usage, ensuring safety and enhancing the overall performance of electronic systems. However, traditional current sensing methods, especially those involving shunt resistors, present several challenges. These methods often require additional amplifiers and filters, which not only consume valuable PCB space but also elevate production costs. Magnetic current sensors emerge as a viable alternative, offering the potential to significantly reduce PCB footprint by integrating multiple discrete components into a single integrated circuit.In our <a href="https://www.wevolver.com/article/next-generation-current-measurement-addressing-pcb-design-challenges-with-magnetic-current-sensors/" target="_blank" rel="noopener noreferrer">Next-Generation Current Measurement series</a>, we've previously explored various challenges associated with traditional current sensing methods. This article focuses specifically on addressing the challenge of size constraints within PCB design and highlights the advantages of magnetic current sensors in modern electronics.<h1 dir="ltr">Current Sensing and Space Constraints</h1>In traditional PCB design, managing current sensing typically involves the use of shunt resistors along with ancillary components such as operational amplifiers, filtering components and gain-setting resistors. These components consume a significant area of the PCB and add complexity to the layout, which makes it challenging to achieve the compactness required by electronic devices.Using a number of components necessitates additional design considerations such as thermal management and precise routing for effective electrical isolation and accurate signal measurement, for instance, ensuring Kelvin connections to the shunt resistor. This complexity can increase the overall PCB size, which in turn raises material costs and necessitates larger enclosures, thereby driving up manufacturing expenses.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNDcyMzAwNzIxLWFiYy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="traditional-shunt-resistor-current-measurement-system">Functional diagram of a traditional shunt resistor-based current measurement systemMagnetic current sensors offer a streamlined solution to this problem by incorporating all necessary functionalities into a single small package.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNjM3MzM3MjY1LTI0MDgxMV9KZXNzLTAyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="magnetic-current-sensor-block-diagram">Functional diagram of a magnetic current sensor in a compact package eliminating several external components required by the shunt resistor-based current sensorsThese integrated magnetic current sensors eliminate the need for external components, which are often larger than the magnetic sensor’s package itself, thereby simplifying the PCB layout and significantly reducing the footprint required for current sensing. This integration enables more efficient use of space and resources in designing advanced electronic systems.<h1 dir="ltr">Minimizing PCB Footprint with Magnetic Current Sensing</h1>Magnetic current sensors represent a breakthrough in current sensing technology by integrating the functions of shunt resistors, shunt amplifiers, and additional filtering components into a single compact integrated circuit (IC). This integration streamlines the design process and drastically reduces the physical footprint on the PCB.<h2 dir="ltr">Comparison with Traditional Shunt Resistors</h2>A typical 1 mΩ shunt resistor in a 2512 package (6.3 x 3.2 mm) occupies a substantial PCB area. In contrast, Allegro’s ACS71240, with a 0.6 mΩ resistance in a 3 x 3 mm QFN package, is 56% smaller, occupying just 9 mm².&nbsp;A complete shunt-resistor-based current measurement circuit, with a resistance of 0.5 mΩ, having similar functionality, consumes 120 mm², making it nearly 13.3 times larger than the ACS71240 solution.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNDY5NDEwNjk0LWltYWdlMy5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="allegro-acs-71240-vs-shunt-resistor-based-current-sensing">Allegro ACS71240 (left) in a 3 x 3 = 9 mm2 package (0.6 mΩ) vs. shunt-based solution (right) along with ancillary components taking up a total of 15 x 8 = 120 mm2 (0.5 mΩ). Image source: Allegro MicroSystemsFor high-current applications, where a 100 µΩ shunt resistor might require an even larger footprint (around 10 x 5.2 mm), Allegro’s ACS37220 in a 4x4 mm QFN package reduces size by 69% by integrating up to 9 distinct components on the board, resulting in substantial space savings.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNDY5MDAyNDAxLWltYWdlNy5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="shunt-resistor-vs-allegro-magnetic-current-sensor-size">The physical size of the resistive element in shunt resistors is often larger than the entire magnetic current sensing solution.These examples highlight how magnetic current sensors can drastically decrease the PCB area required for current sensing.<h1 dir="ltr">Key Benefits of Magnetic Current Sensors</h1>The integration of magnetic current sensors into PCB designs provides several distinct advantages specifically related to addressing size constraints, a critical issue highlighted in our previous discussion. These benefits offer compelling solutions over traditional shunt-based approaches where space is limited.<h2 dir="ltr">Reduced PCB Area</h2>Integration Efficiency: By combining the functionalities of current sensing, amplification and filtering into a single component, magnetic current sensors significantly decrease the PCB footprint. This is beneficial in applications where space is scarce, such as in automotive systems.Simplified Layout: The reduced number of components simplifies the PCB layout to minimize the need for additional wiring and routing, which can complicate the assembly process and increase the risk of errors.<h2 dir="ltr">Cost Efficiency</h2>Lower Material Costs: Smaller PCBs require less material, which directly reduces the cost of the product of which they are a part. Additionally, smaller boards can fit into smaller enclosures, which are often less expensive and reduce the overall material expenditure for the product.Reduced Assembly Costs: With fewer components to place and solder, assembly time and costs are reduced. This streamlined assembly process can also decrease the likelihood of manufacturing defects to further reduce costs associated with quality control and rework.<h2 dir="ltr">Design Flexibility</h2>Innovative Product Design:&nbsp;The space savings provided by magnetic current sensors enable designers to either reduce the size of the existing products or use the available space for additional functionality, which potentially differentiates their products in competitive markets.Enhanced Performance and Reliability:&nbsp;With fewer components involved, the overall reliability of the PCB can increase as there are fewer potential points of failure. Additionally, the integrated design of magnetic sensors often comes with improved performance characteristics, such as enhanced noise immunity and better thermal management.These benefits make magnetic current sensors an attractive option for a wide range of applications, particularly those where innovation and cost-effectiveness are crucial.<h1 dir="ltr">Case Study: Real-World Application and Benefits</h1>A compelling example of the benefits offered by magnetic current sensors can be seen in the experience of a global industrial robot manufacturer. This company faced significant challenges in incorporating traditional shunt resistors into their designs due to the large size and complex integration requirements. The small form factor required for their advanced robotic systems made traditional current sensing methods impractical.<h2 dir="ltr">Challenge Faced</h2>The manufacturer needed a current sensing solution that could fit within the stringent size constraints of their robotic systems without compromising on performance. Traditional shunt resistors, along with their auxiliary components, were simply too bulky and would have necessitated design compromises that could affect the overall functionality of the robots.<h2 dir="ltr">Solution Delivered</h2>The company opted to integrate Allegro’s ACS71240 magnetic current sensors into their designs. These sensors offered a much smaller footprint compared to the shunt resistors previously considered. The ACS71240 sensors, housed in compact 3x3 mm QFN packages, provided the necessary current sensing capabilities while meeting the size requirements imposed by the compact robotic designs.<h2 dir="ltr">Outcome Achieved</h2>The transition to magnetic current sensors enabled the manufacturer to achieve several key improvements:<ul><li dir="ltr">Space Efficiency: The smaller sensors allowed for a more compact overall design, crucial for the intricate internal layouts of their robots.</li><li dir="ltr">Enhanced Performance: With integrated signal conditioning and improved accuracy over traditional methods, the sensors delivered more reliable and precise current measurements.</li><li dir="ltr">Cost Reduction: By reducing the PCB size and simplifying the assembly process, the manufacturer could lower both production costs and time-to-market for their robotic systems.</li></ul>This case study is proof of the drastic impact that magnetic current sensors can have on product design and manufacturing.<h1 dir="ltr">Overcoming Size Challenges in PCB Design with Magnetic Current Sensors by Allegro MicroSystems</h1>Innovations in current sensing technology are crucial for enhancing the efficiency and functionality of PCB designs in constrained spaces. <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-1&utm_content=landing-page" target="_blank">Allegro MicroSystems</a> offers a range of integrated solutions that cater to different needs, from high-current applications to compact, high-voltage environments.<a href="https://www.allegromicro.com/en/products/sense/current-sensor-ics/zero-to-fifty-amp-integrated-conductor-sensor-ics/acs37041?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-1&utm_content=landing-page" target="_blank">Allegro ACS37041</a>: This sensor, enclosed in a compact SOT23-W package, supports bidirectional current measurement up to 30 A and operates up to 100 V(RMS). Its low resistance of 1.6 mΩ and error below ±5% across the temperature range make it ideal for various applications where board space is limited but precise current measurement is crucial.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNjM3MzYyNjI5LTI0MDgxMV9KZXNzLTAxLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 832px;" class="fr-fic fr-dib" alt="Allegro-ACS37041-magnetic-current-sensor">Image Caption<a href="https://www.allegromicro.com/en/products/sense/current-sensor-ics/fifty-to-two-hundred-amp-integrated-conductor-sensor-ics/acs37220?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-1&utm_content=landing-page" target="_blank">Allegro ACS37220</a>: Designed for high-current applications, this sensor comes in a 4 x 4 mm QFN package, can handle up to ±200 A, and operates under 100 V(RMS). It features an ultra-low 100 μΩ resistance conductor and is AEC-Q100 certified, optimal for automotive and data center applications where high reliability and performance are required under stringent conditions.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNzMzODI4MDc5LTI0MDcyMV8wNi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="allegro-acs-37220-magnetic-current-sensor">ACS37220 Magnetic current sensor by Allegro MicroSystems in a 7-pin 4 x 4 mm QFN package<a href="https://www.allegromicro.com/en/products/sense/current-sensor-ics/zero-to-fifty-amp-integrated-conductor-sensor-ics/acs71240?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-1&utm_content=landing-page" target="_blank">Allegro ACS71240</a>: Available in 3mm x 3mm QFN and SOIC8 packages, this sensor measures currents up to 60 A (QFN) and 55 A (SOIC8), and withstands voltages up to 420 V(Peak) and 297 V(RMS). Key features include immunity to stray magnetic fields, fast overcurrent fault output and AEC-Q100 qualification, which makes it ideal for applications that require compact design in high-voltage environments.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzNjM3Mzg1MDI2LTI0MDgxMV9KZXNzLTAzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="allegro-acs-71240-magnetic-current-sensor">ACS71240 Magnetic current sensor by Allegro MicroSystems in a 12-pin 3 x 3 mm QFN package and an 8-pin SOIC packageTogether, these sensors demonstrate <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-1&utm_content=landing-page" target="_blank">Allegro</a>’s commitment to providing scalable solutions for PCB designs that demand high performance in space-constrained environments. Each sensor is tailored to meet specific application needs to ensure that design engineers have the right tools to address modern electronic challenges efficiently.<h1 dir="ltr">Conclusion</h1>As electronic devices continue to shrink, the need for compact and efficient design solutions becomes increasingly critical. Magnetic current sensors address this challenge by integrating multiple functions into a single, small component that significantly reduces PCB footprint and enhances design flexibility. These sensors minimize material and production costs and simplify assembly processes, thus resulting in more reliable and efficient products.&nbsp;&nbsp;<iframe id="66b5d68ec139c9048fd77925" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/allegro-acs37041-integrated-hall-effect-current-sensor?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>The transition to magnetic current sensors, as demonstrated by the case study with the industrial robot manufacturer, highlights their ability to meet stringent design requirements while improving performance. As the trend towards miniaturization persists, magnetic current sensors are set to become a crucial element in advanced electronic designs and offer engineers a vital tool to innovate and optimize compact electronic systems.Visit <a href="https://www.allegromicro.com/en/products/emerging-technologies/replace-the-shunt?utm_source=wevolver&utm_medium=article&utm_campaign=punt-the-shunt&utm_term=article-1&utm_content=landing-page" target="_blank">Allegro MicroSystem's official website</a> today to find the optimal solution for your current measurement needs.<hr>This article is a part of Next-Generation Current Sensing, a series that delves into cutting-edge developments in current measurement.&nbsp;Articles featured in the series:<ul><li dir="ltr"><a href="https://www.wevolver.com/article/next-generation-current-measurement-addressing-pcb-design-challenges-with-magnetic-current-sensors" target="_blank" rel="noopener noreferrer">Next-Generation Current Measurement: Addressing PCB Design Challenges with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-size-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Size Challenges in PCB Design with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-heating-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Heating Challenges in PCB Design with Magnetic Current Sensors</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/overcoming-complexity-challenges-in-pcb-design-with-magnetic-current-sensors" target="_blank">Overcoming Complexity Challenges in PCB Design with Magnetic Current Sensors</a></li></ul>

Article 1 of Next-Generation Current Measurement Series: Magnetic current sensors provide a compact and efficient alternative to traditional current measurement techniques that significantly reduce the size of components on PCBs, crucial for space-constrained electronic designs.

Overcoming Size Challenges in PCB Design with Magnetic Current Sensors

Introducing the Next-Generation Current Measurement Series: Advanced magnetic current sensors accurately detect magnetic fields generated by current flow, offering precise current level measurements.

Next-Generation Current Measurement: Addressing PCB Design Challenges with Magnetic Current Sensors

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