Metal Strip Current Sense Resistors

What is Metal Strip Current Sense Resistors

 

Eaton's metal plate resistors (also known as metal strip current sense resistors ) are constructed with a metal plate with epoxy overcoat and end terminations to provide low temperature coefficient of resistance (TCR), low resistance and high power capability.

Benefits of Metal Strip Current Sense Resistors

 

 

Low Inductance
Inductance is typically an unwanted property in resistors, particularly in filter circuits. All conductors have inductance, the value depends on its geometry. Generally a wide, flat and short geometry will have lower inductance than a thin, wound long conductor. This is where printed conductive ink allows resistor elements to be formed on wide flat ceramic insulating substrate. This delivers a very low inductance resistor.
Thick film resistors, with lower stray inductance, are therefore the preferred metal strip current sense resistors type for high frequency applications like PWM filters or current shunts.

 

Heat dissipation
Dissipating heat from a metal strip current sense resistors is all about surface area and the interface to a cooler medium. Thick film resistors enable a large flat surface area, meaning they are easy to attach to a heat sink or cold plate. Power dissipation of 2 kW is possible in 60mm square.

 

High Isolation voltage
A power resistor printed onto a ceramic substrate has an intrinsic isolation from the terminals to the base plate. This can be is enhanced with coatings (polyimide for example) applied to the resistor element. The ceramic substrate is then placed in a supporting mechanical housing which is filled with a silicone gel to complete the electrical isolation solution. Isolation rating of up to 12 kVrms to the baseplate can be achieved in a range of ultra high power resistors.

 

Robust construction
Thick film metal strip current sense resistors are more mechanically robust than wirewound resistors, which makes them less susceptible to damage as a result of poor handling or packaging, or rough insertion into a system.
Further, their construction involves constructive paint being screen printed and fired onto an insulating substrate, usually a ceramic base, making it a permanent assembly. This construction makes the resistors better at dealing with high power surges than their wirewound counterparts.
The ceramic layer – with the resistor printed onto it – is housed in a custom designed plastic case for protection, which also can incorporate mounting hardware. The housing also can have a spring installed to manage the pressure needed to reliably achieve good thermal contact without cracking the ceramics.

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How To Use A Metal Strip Current Sensing Resistor

 

To measure resistance:
 Turn power to circuit OFF.
• If a circuit includes a capacitor, discharge the capacitor before taking any resistance reading.

 

 Turn digital multimeter dial to resistance, or ohms, which often shares a spot on the dial with one or more other test/measurement modes (continuity, capacitance or diode; see illustration below).
• The display should show OLΩ because, in Resistance mode, even before test leads are connected to a component, a digital multimeter automatically begins taking a resistance measurement.
• The MΩ symbol may appear in the display because the resistance of open (unattached) test leads is very high.
• When the leads are connected to a component, a digital multimeter automatically uses the Autorange mode to adjust to the best range.
• Pressing the Range button allows a technician to manually set the range.
• Best results will be achieved if the component to be tested is removed from the circuit. If the component is left in the circuit, the readings could be affected by other components in parallel with the component to be tested.

 

 First insert the black test lead into the COM jack.

 

 Then insert the red lead into the VΩ jack.
• When finished, remove the leads in reverse order: red first, then black.

 

 Connect test leads across the component being tested.
• Make sure that contact between the test leads and circuit is good.

Tip: For very low-resistance measurements, use the relative mode (REL; see point 11). It may also be referred to as zero or Delta (Δ) mode. It automatically subtracts test lead resistance—typically 0.2 Ω to 0.5 Ω. Ideally, if test leads touch (are shorted together), the display should show 0 Ω.
Other factors that can affect resistance readings: Foreign substances (dirt, solder flux, oil), body contact with the metal ends of the test leads, or parallel circuit paths. The human body becomes a parallel resistance path, lowering total circuit resistance. Thus, avoid touching metal parts of test leads to avoid errors.

 

 Read the measurement on the display.


 When finished, turn the multimeter OFF to prevent battery drain.
Advanced digital multimeter options

 

  Press the RANGE button to select a specific fixed measurement range.
• Be sure to note the annunciator (such as K or M) after the measurement in the display.

 

 Press the HOLD button to capture a stable measurement—it can be viewed later.

 

 Press the MIN/MAX button to capture the lowest and highest measurement.
• The multimeter beeps each time a new reading is recorded.

 

 Press the relative (REL) button to set the multimeter to a specific reference value.
• Measurements above and below the reference value are displayed.

 

SMD 0805 Resistors

Metal Strip Current Sense Resistor Performance Specifications

 

Current sensing metal strip current sense resistors informationnumber of terminals- Most current resistors have either two or four terminals.

 

Resistance range - Resistance range is measured in ohms.

Tolerance - Tolerance is specified as percentage.

 

Power rating - Power rating is the maximum power level that a current sensing resistor supports.

 

Continuous operating voltage - The continuous operating voltage is measured in volts.Temperature coefficient parameter (TCP) - The temperature coefficient parameter (TCP) measures the rate at which the nominal resistance value changes as a function of temperature. Typically, TCP is expressed as parts-per-million per degree Celsius (ppm/C).

 

Operating temperature - Operating temperature is an important environmental parameter to consider, escially for current sensing metal strip current sense resistors which are exposed to flow, reflow, or wave soldering.

Metal Strip Current Detection Resistor Installation Method

 

Metal strip current sense resistors informationbolt-on to a chassis - By attaching solidly to a metal surface, these chassis-mounted resistors provide maximum heat dissipation.

 

Surface mount technology (SMT) - SMTadds current resistors to a printed circuit board (PCB) by soldering component leads or terminals to the top side of the board. Typically, the PCB pad is coated with a paste-like formulation of solder and flux.

 

Through-hole technology (THT) - Current sensing resistors that use THT are mounted on a PCB by inserting component leads through holes in the board, and then soldering the leads in place on the opposite side of the board.

SMD 0805 Resistors

 

How Do You Choose the Right Metal Strip Current Sense Resistors ?

Resistance value

This is the most important factor to consider when choosing a metal strip current sense resistors . The resistance value determines the amount of voltage drop across the resistor, which is proportional to the current flowing through it. For example, a 0.1Ω resistor will produce a 100mV voltage drop for every 1 Amp of current flowing through it.

Power rating

The power rating of a metal strip current sense resistors is the maximum amount of power it can dissipate without being damaged. It is essential to choose a resistor with a power rating that is high enough to handle the maximum amount of current that will flow through it.

 

Temperature coefficient

The temperature coefficient of a metal strip current sense resistors is the amount that its resistance value will change for every degree change in temperature. It is important to choose a resistor with a low-temperature coefficient to minimize the effects of temperature changes on the voltage drop across the resistor.

Tolerance

Tolerance is the amount a metal strip current sense resistors resistance value can vary from its nominal value. Choosing a resistor with a low tolerance is vital to ensure that the voltage drop across the resistor is as accurate as possible.

 

 

Types of Metal Strip Current Sense Resistors

 

Wire wound resistor
A form of a passive component is called a wire-wound resistor. A wire wound resistor is created by wrapping metal wire around a metal core. The metal wire serves as the electric current’s resistive component. Thus, the metal wire restricts a specific level of electric current. As a non-conductive substance, the metal core is placed. As a result, it blocks the flow of electric current.

 

Foil resistor
The most precise and reliable parts to employ to limit the flow of electric current to a specific level are foil resistors. Compared to other types of resistors, foil resistors generate little noise. The TCR (Temperature Coefficient of Resistance) of foil resistors is low.

 

Carbon composition resistor
A passive component that limits the flow of electric current to a set level is a resistor made of carbon called a carbon composition resistor. The cylindrical resistive element used to create the carbon composition resistors has integrated metal end caps. The ceramic and carbon powder combination is used to create the cylindrical resistive element of the carbon composition resistor. The carbon powder effectively conducts electric current.

 

Carbon film resistor
The carbon film resistor is the most common type of resistor used in electrical circuits. The carbon film is applied to a ceramic substrate to create the carbon film resistors. The ceramic substrate serves as an electrical current insulator, while the carbon sheet functions as a resistive element to the current.

 

Metal film resistor
A form of a passive component known as a metal film resistor uses metal film to limit the flow of electric current to a specific level. In contrast to metal film resistors, which use chromium, nickel, tin, and antimony to create their films, carbon is used to create the film in carbon film resistors. The TCR (temperature coefficient of resistance) of metal film resistors is low.

 

Metal glaze resistor
The metal glaze resistor is a passive component used to limit the flow of electric current to a certain level by combining glass powder with metal particles. Low TCR (temperature coefficient of resistance) for metal glaze resistors.

 

Metal oxide film resistor
A form of a passive component known as a metal oxide film resistor uses metal oxide film as the resistive element to limit the flow of electric current to a specific level. Metal oxide film resistor construction is virtually identical to metal film resistors.

 

 
Our Factory

 

The 1st team release high temperature Pt thin film sensor in Taiwan in1999

• The 1st team release current sensing resistor in Taiwan by lithography

process in 2000

• The 1st team release thin film high freq. chip inductor in size 0402 and 0603

in Taiwan in 2002

• Complete series of thin film resistor in size 0201 ~ 2512 in Taiwan in 2003

• The 1st team release thin film chip fuse in Taiwan in year 2004

• The 1st team release thin film ESD suppressor worldwide in 2005

• 1st team release thick film printing NTC thermistor in Taiwan in 2006

• The 1st team release thin film current sensing resistor in Taiwan in 2007

• The 1st team release Shunt CSR in Taiwan in 2012

The 1st team release high temperature Pt thin film sensor in Taiwan in1999

• The 1st team release current sensing resistor in Taiwan by lithography

process in 2000

• The 1st team release thin film high freq. chip inductor in size 0402 and 0603

in Taiwan in 2002

• Complete series of thin film resistor in size 0201 ~ 2512 in Taiwan in 2003

• The 1st team release thin film chip fuse in Taiwan in year 2004

• The 1st team release thin film ESD suppressor worldwide in 2005

• 1st team release thick film printing NTC thermistor in Taiwan in 2006

• The 1st team release thin film current sensing resistor in Taiwan in 2007

• The 1st team release Shunt CSR in Taiwan in 2012

 

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Asked Questions
 

Q: How do current sensing resistors work?

A: Current sense resistors work by detecting and converting current to voltage. These devices feature very low resistance values, and therefore, cause only an insignificant voltage drop of 10 to 130 mV in the application.

Q: What is the function of metal strip resistor?

A: Current sensing Power Metal Strip resistors allow control circuitry to monitor the level of current in a circuit by translating current into a voltage that can be monitored easily.

Q: What is the tolerance of a current sense resistor?

A: With resistance tolerances of 1%, the component can handle a pulse current up to 500A/0.5sec, depending on ohmic values. These bare metal element resistors are offered in 3 standard power ratings, 0.25, 0.50, and 1.0 watt, with a resistance range from 0.002 ohms to 0.008 ohms in standard 5% tolerance.

Q: What are the applications of current sense resistor?

A: Current sense resistors are used in various applications, including power supplies, motor controllers, and overcurrent protection circuits. They are often used in conjunction with op-amps or other amplifiers to increase the strength of the measurement.

Q: What is the purpose of current sensing?

A: These sensors provide an intrinsic electrical isolation between the current to be measured and the output signal, thus making these current sensing devices mandatory, where safety standards demand electrical isolation.

Q: Why is current sensing important?

A: Current sensing and measurement are important in applications such as power conversion, battery charging, and industrial processes. Different current sensing technologies are used, depending on whether the measurement is for alternating current (AC) or direct current (DC) and how much current needs to be measured.

Q: What are the three main functions of a resistor?

A: A resistor is a two-terminal electrical component that provides electrical resistance. In electronic circuits, resistors are predominantly used to lower the flow of current, divide voltages, block transmission signals, and bias active elements.

Q: Why do I need a resistor?

A: It's counter-intuitive, but even though energy is dissipated with resistance, resistors are absolutely essential to the proper functioning of electronics. They function to ensure that other components aren't provided with too much voltage or electric current.

Q: How do you calculate the value of a current sense resistor?

A: Therefore, the current sense resistor value needs to meet the formula R=V/I, so the calculated value will be 0.1V / 2A = 0.05Ω or 50mΩ. The resistor needs to have a power rating of P=I2R or P= 22 x 0.05 = 0.2W. The closing value of the current sense resistor is 50mΩ, and 1% of rating, that is 0.25W.

Q: What is the difference between a current sense resistor and a normal resistor?

A: Current Sense Resistors are similar to normal resistors but with very low resistance rating and high-power rating. These shunt resistors of known resistor value (R) are placed in a current conducting path so that the entire current (I) which is to be measured flows through the resistors.

Q: How do you calculate sense resistor value?

A: The maximum shunt resistor value is calculated as the ratio of the full-scale output voltage of the amplifier divided by its gain all divided by maximum load current. It should be noted that full-scale output range depends on the device supply and its output swing limitation.

Q: How does current detector work?

A: The current carrying conductor placed through the aperture of the sensor produces a magnetic field that is proportionate to the current. This field is concentrated by the core and sensed by the Hall generator. The Hall generator is connected to the input of the current amplifier, which drives the coil.

Q: What are the advantages of current sensors?

A: The resistance value of the primary conductor is small, so that the heat generation is low. Less numbers of parts are needed (No need to use other peripheral parts.)

Q: What is the sensitivity of a current sensor?

A: With provision to be factory calibrated for zero-current output point and sensitivity, each of these devices produces a linear analog output that is proportional to the current flowing directly through the IC's leadframe.

Q: What are the advantages and disadvantages of current sensors?

A: Current sensors offer several advantages such as real-time current monitoring, preventing circuit overloads, and improving energy efficiency. However, they also come with some limitations. For example, transformers cannot measure DC currents, and Hall-effect sensors may be influenced by external magnetic fields.

Q: Is a current sensor analog or digital?

A: Current is measured by sensors that quantify the flow of electrons through wires. Sensors are available for both AC and DC electrical systems. Current sensors can provide either analog or digital outputs. A digital current sensor acts as a switch that operates when current exceeds or drops below a set limit.

Q: What is the difference between resistance and resistor?

A: Hence, the basic difference between resistance and resistor is that Resistor is an electrical component especially designed to offer resistance in electrical circuits while resistance is the property of a material which opposes the flow of electricity through it.

Q: What is the most important use function of a resistor?

A: The name itself mention it's function. Resistor is used to resistance the flow of current. When resistor is placed in a circuit, the current flow decreases when current passes through the resistor. The part of current energy dissipate in the form of heat in resistor, thus decrease the total current.

Q: What's inside a resistor?

A: The resistive element is made from a mixture of fine carbon particles and a non-conductive ceramic material. The substance is pressed into a cylindrical shape and baked. The resistance value depends on the dimensions of the body and the ratio between carbon and ceramic material. More carbon means a lower resistance.

Q: Does the direction of a resistor matter?

A: Does the direction of a resistor matter? No! Unlike many other components, resistors do not have polarity, meaning you can install them in either direction on a circuit.

As one of the leading metal strip current sense resistors suppliers in China, we warmly welcome you to buy discount metal strip current sense resistors from our factory. All customized products are with high quality and competitive price. For quotation and free sample, contact us now.

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