Improve pad layout to optimize high current detection accuracy

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Overview:
Current sense resistors are available in a variety of shapes and sizes to measure current in many automotive, power control, and industrial systems. When using extremely low value resistors (several mΩ or less), the resistance of the solder will occupy a large proportion of the resistance of the sensing element, resulting in a large increase in measurement error. High-precision applications typically use 4-pin resistors and Kelvin detection techniques to reduce this error, but these dedicated resistors can be expensive. In addition, the size and design of the resistor pad plays a key role in determining the accuracy of the measurement when measuring large currents. This article describes an alternative that uses a standard low-cost dual-pad sense resistor (4-pad layout) for high-precision Kelvin detection. Figure 1 shows the test board used to determine the error caused by five different layouts.

Figure 2 (a) Outline dimensions of ULRG3-2512-0M50-FLFSLT resistors; (b) Standard 4-pad package

(Please read the PDF for details)