As AI infrastructure, industrial robotics, battery management systems (BMS) and advanced power electronics drive increasing power density and efficiency requirements, accurate current sensing is becoming increasingly critical.
At the same time, engineers are under increasing pressure to improve energy efficiency and reduce system costs, while maintaining measurement accuracy in higher power designs. To address these challenges, Panasonic Industry offers its thick film current sensing resistors as a cost-effective alternative to conventional metal shunt resistors for selected low- and medium-current sensing applications.
Current sense resistors play a vital role in measuring electrical current and enabling its monitoring and control in applications ranging from AI server power systems and industrial robotics to battery management systems,
DC/DC converters, motor drives and advanced power supplies. Accurate current detection and control support improved system performance, system protection and higher energy efficiency.
Traditionally, metal shunt resistors have been widely used for current sensing, particularly in applications requiring very low resistance values and high power-handling capabilities. However, not all current-sensing applications require ultra-low resistance values or the highest power ratings. In low- and medium-current designs with suitable electrical and thermal requirements, thick film current sense resistors can provide the required sensing performance, while helping to reduce component cost.
A key challenge in current sensing is balancing low resistance with a low temperature coefficient of resistance (TCR), as these requirements typically involve a trade-off. Panasonic addresses this challenge through optimised resistor materials and component structures that support accurate current measurement, low power loss through low resistance values, improved heat dissipation and reduced temperature-induced drift.
For engineers working within the operating range in which thick-film and metal-shunt technologies overlap, Panasonic’s thick film current sensing resistors offer several important advantages:
• Potential component cost savings of up to 50% compared with selected comparable metal shunt solutions in suitable applications.*
• Improved heat dissipation through optimised component design, such as wide-terminal structures and double-sided resistive element structures, helping to lower operating temperatures and enhance thermal performance.
• Enhanced reliability under thermal cycling, supported by soft termination technology that helps reduce solder-joint stress.
• Supports accurate current sensing with resistance values down to 10 mΩ, stable resistance performance over temperature and TCR values as low as ±75 ppm/°C in selected series.
• Simplified migration through footprint-compatible designs available in selected case sizes, supporting the replacement of metal shunt resistors within the overlapping operating range.
* Panasonic estimation. Actual savings may vary depending on specifications, purchase volume and application requirements.
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