The current sensor of the outdoor charging pile needs to maintain high performance and high reliability in complex outdoor environments. Its requirements cover multiple dimensions such as environmental tolerance, electrical performance, and safety protection. The following are key requirements and technical analysis:

 

 

1.Environmental tolerance requirements

Stability over a wide temperature range

– The operating temperature range must cover -40°C to +85°C (some scenarios require support for 150°C), and low drift must be maintained under extreme temperature differences (zero drift ≤±10mV, gain drift ≤±1.5%).

– Avoid measurement errors caused by temperature changes, which may affect the current control accuracy of the battery management system.

Moisture and corrosion resistance

In high humidity environments (such as rainy days), the protection level must be IP65 or above to prevent water vapor intrusion that may cause short circuits or reduced accuracy.

The patented design uses a humidity sensor to link with the current monitoring strategy** to adjust the detection threshold in real time and predict the risk of leakage.

Anti-pollution and mechanical strength

The housing must be made of UL94-V0 flame-retardant material to resist corrosive pollutants such as sand, dust, and salt spray, while meeting fire safety standards.

2.Electrical performance requirements

Wide dynamic range and high precision

The measuring range must cover 0~300A and above (to meet fast charging requirements), and the full-range accuracy must be within ±1% to ensure charging efficiency and battery safety.

For example, the  HYCA series supports multiple ranges from 5 to 100A, with extremely low insertion loss, reducing accuracy drift caused by heat.

High-speed response and high bandwidth

The response time is ≤2.5μs and the bandwidth is ≥250kHz to capture abnormalities such as surge current and instantaneous short circuit in the initial charging stage, thus gaining critical response time for the protection circuit.

Low power consumption and anti-interference capability

The power consumption itself needs to be extremely low (such as no insertion loss design) to avoid increasing the heat dissipation burden of the module.

It needs to withstand 8000V electrostatic discharge and complex electromagnetic interference and comply with IEC 61800-5-1 standards.

Safety and reliability requirements

High insulation and voltage resistance

The insulation withstand voltage between the primary and secondary sides must reach AC 4.8kV/50Hz/1min (meeting CATⅢ, PD2 levels) to ensure the personal and equipment safety of high-voltage side current detection.

Multiple security protection mechanisms

Combining leakage current monitoring (fluxgate technology, accuracy 0.005%) and temperature sensor, multiple protections against overload, short circuit and leakage are achieved.

Liquid-cooled charging piles need to have built-in temperature sensors to monitor cable temperature rise in real time and link the cooling system to prevent overheating.

Long-term stability and lifespan

The annual drift needs to be less than 5μA to adapt to long-term outdoor operation; some solutions require a lifespan of more than 100,000 hours.

Installation and Integration Features

1.Miniaturization and Lightweighting

The volume needs to be adapted to high-density fast-charging modules (such as the HYCA-09 which weighs only 0.025g), and support surface mounting (SOP packaging) to improve space utilization.

HYCA-09

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