Current sensor device and method for assembling the device

Abstract

The present invention relates to a current sensor device for monitoring the current flowing through an electric brush, comprising: - an electric brush holder (12) extending along a longitudinal direction and defining a through housing intended to accommodate the electric brush, such that an end of the electric brush intended to brush against a rotating movable surface protrudes from the electric brush holder; - a Hall effect sensor (14) arranged to detect a magnetic field; - a concentrator (16) for concentrating the magnetic field in a concentrated magnetic field region and for protecting this region from external magnetic fields, wherein: - the concentrator (16) is mounted on the electric brush holder (12) so as to surround at least part of the housing of the electric brush holder; - the Hall effect sensor is mounted on the electric brush holder (12) at a location within the concentrated magnetic field region.

Description

[0001] This invention relates to measuring the current flowing through brushes intended to provide electrical contact between stationary and movable parts / elements. The invention can be applied, for example, to rotating electric machines (especially asynchronous motors), motors, and generators (especially wind turbine generators).

[0002] A brush is a sliding electrical contact that transmits current between a stationary part / element and a rotating part / element, and vice versa. Brushes can be used in electrical equipment such as generators or electric motors, and their rotating elements can be current collectors or a set of slip rings. Generally, a brush consists of one or more blocks of conductive material (usually graphite-based) and is typically equipped with cables. These brushes are supported by brush holders.

[0003] The operation of brushes can depend on many parameters, such as ambient temperature, the condition of the contact surfaces, the current passing through each brush, vibration, etc. In high-power machines, multiple brushes are electrically connected in parallel. Therefore, the current is distributed among the brushes, which can interfere with brush operation in cases of asymmetrical current distribution: a brush with low current passing through it will act as a grinding stone, while another brush with high current passing through it will become hot. The resistance of the latter will increase, especially at the connection points of the cables to the brushes. This increase in resistance can potentially cause the brush to disconnect by pulling out the cables, increasing the current through other brushes, and ultimately possibly pulling out all the cables connected to the brushes.

[0004] This is why monitoring the current through the brushes has been essential for users of rotating motors for several years.

[0005] The current through the brushes can be monitored using a current sensor resistor (“shunt sensor” or “current sensing resistor”). This system is inexpensive and widely used. However, due to the large size of the device, some current may be lost, and it is difficult to monitor each brush.

[0006] Using Hall effect sensors to measure the current passing through brushes is known. Hall effect sensors are sensitive to the magnetic flux generated by the current and produce a voltage representing that current. Such sensors have the advantage of not interfering with the current being measured. However, interference and losses can be observed due to the sensitivity of these sensors to the magnetic environment and external magnetic sources. Furthermore, installation is generally relatively complex, as these sensors are typically mounted on the cable that powers the brushes.

[0007] Document CN102169136 specifically describes a device for online monitoring of brush current in a generator. This device includes a Hall effect sensor mounted upstream of the brushes, which is connected to the power board of the brush holder via a cable. Therefore, the Hall effect sensor does not measure the current through the brushes, but only the current through the power board.

[0008] It is known to use Hall effect sensors to measure the current in the cable connected to the brush. Therefore, document RU2157033C1 describes a tool for measuring the current in the cable connected to the brush. However, this tool requires operator intervention and cannot measure the current through the brush block, but only the current through the cable connected to the brush.

[0009] Document CN107861062B describes a device for online monitoring of a generator using a Hall effect sensor located between the two ends of a ring supporting the winding, or in other words, at the active toroidal surface. The sensor output signal of the Hall effect sensor represents the change in current through one or more brushes. Therefore, the Hall effect sensor does not measure the current value. The document also does not specify the location of the Hall effect sensor.

[0010] Therefore, there is a need for a current sensor device that enables reliable and efficient monitoring of the brushes in a rotating electric machine. There is also a need for a compact, inexpensive, and easy-to-install current sensor device.

[0011] A current sensor device for monitoring the current through a brush is proposed, the current sensor device comprising:

[0012] - A brush holder extends longitudinally between a distal and a proximal end and defines a through-house, the through-house intended to slidably receive a brush in the longitudinal direction, such that one end of the brush intended to slide against a rotationally movable surface protrudes from the brush holder on the same side of the distal end of the brush holder.

[0013] - Hall effect sensor, a Hall effect sensor is arranged to detect magnetic fields.

[0014] - A concentrator, arranged to focus the magnetic field within a concentrated magnetic field region and protect that region from the influence of external magnetic fields, wherein...

[0015] - The concentrator is mounted on the brush holder so that when the brush is received within the housing of the brush holder, it surrounds at least a portion of the brush in a plane perpendicular to the longitudinal direction.

[0016] - A Hall effect sensor is mounted on the brush holder at a location within a concentrated magnetic field region so as to measure a value representing the intensity of the current passing through the brush when the brush is received in the housing of the brush holder.

[0017] Therefore, when the brush is housed in the brush holder housing, a concentrator surrounds at least a portion of the brush, such that the magnetic field generated by the current passing through the brush is concentrated by the concentrator. The presence of the concentrator allows for the concentration and amplification of the magnetic flux generated by the current passing through the brush housed in the brush holder, thus improving measurement accuracy. The concentrator also allows for the protection of the Hall effect sensor from magnetic fields from external sources. Furthermore, such an arrangement is compact, allowing for a current sensor for each brush holder and therefore each brush, improving the monitoring of rotating motors equipped with multiple brushes.

[0018] It should be noted that the concentrator can be mounted outside the brush holder so as to at least partially surround the housing. The concentrator then surrounds the wall of the brush holder that defines the housing. The concentrator can also be mounted inside the brush holder so as to at least partially surround the housing. In this case, the concentrator can at least partially define the housing and is itself surrounded by the wall of the brush holder. In other words, in all cases, the concentrator is mounted on the brush holder so as to at least partially surround the brush disposed within the housing.

[0019] Advantageously, Hall effect sensors can be sensitive to magnetic fields extending parallel to their surface. For example, using Sensors using (integrated magnetic concentrator) technology are a prime example. This type of sensor can then be positioned to extend parallel to the longitudinal direction of the brush holder in order to measure the current flowing in the longitudinal direction. This allows for further limitations on the size of the current sensor device.

[0020] The Hall effect sensor and concentrator can be positioned at any point along the longitudinal direction of the brush holder. However, at the proximal end of the brush holder, i.e., opposite the distal end to which the brush slides against a rotating movable surface, the current through the brush flows in three directions: in the longitudinal direction, but also in two directions perpendicular to the longitudinal direction. When placed in this region, the Hall effect sensor will therefore not measure the entire current.

[0021] Therefore, advantageously, for better measurement accuracy, the concentrator and Hall effect sensor can be located closer in the longitudinal direction to the distal end of the brush holder than to the proximal end. In use, the concentrator and Hall effect sensor are then located closer to the end of the brush that slides against the rotating movable surface. In this region of the brush, the current flows substantially in the longitudinal direction, making it possible to measure all or almost all of the current passing through the brush. In particular, the concentrator and Hall effect sensor can be located at the distal end of the brush holder.

[0022] The concentrator can completely surround the brush housed in the brush holder in a plane perpendicular to the longitudinal direction, or it can have an open form.

[0023] Advantageously, the housing can have a quadrilateral cross-section in a plane extending perpendicular to the longitudinal direction of the brush holder, and the concentrator can therefore surround the brush received within the housing on at least three sides of the quadrilateral shape of the housing in the same plane, or even partially or entirely on a fourth housing side. This shape of the concentrator is easy to achieve and allows for particularly effective concentration of the magnetic field generated by the current through the brush, while limiting magnetic fields generated by adjacent brushes and / or interference from external sources. The concentrator can particularly have a U-shape, and the sensor is advantageously positioned at the opening of the U between the wings, particularly midway between the wings of the U.

[0024] Generally, a concentrator can be shaped like a brush holder and applied against the wall forming the brush holder, either outside or inside the brush holder.

[0025] Advantageously, the Hall effect sensor can be attached to a sensor support located within a housing mounted on the brush holder, allowing the Hall effect sensor to be removably mounted on the brush holder. This removable mounting of the Hall effect sensor can result in a removable mounting of the housing on the brush holder, a removable mounting of the sensor support on the housing, or both. Therefore, the Hall effect sensor can be easily mounted on or removed from the brush holder, allowing for easy and quick installation or even replacement. For example, the housing receiving the sensor support can be secured to the brush holder by clips, or the sensor support can be inserted into the housing like a box.

[0026] Therefore, at least one element selected from the housing and sensor support can be removably mounted, particularly without tools. This removable mounting can be achieved, for example, by means of a convex or concave element that cooperates with a corresponding concave / convex element of the brush holder or housing. These corresponding convex / concave elements can be, for example, selected from slide rails / finger members, snap-fit ​​holes / finger members, snap-fit ​​holes / lugs, other types of convex / concave elements of the slider / rail type, and combinations thereof.

[0027] In the variant, the Hall effect sensor can be fixedly (non-removably) mounted on the brush holder, or directly (by gluing, etc.) mounted on the brush holder, or via a sensor support fixedly mounted on the brush holder (by gluing, screwing, etc.), or via a sensor support located inside a housing fixedly mounted on the brush holder (by gluing, screwing, etc.).

[0028] Generally, the sensor support can extend parallel to the longitudinal direction, preferably parallel to the surface of the brush holder.

[0029] Advantageously, the sensor support can be a printed circuit board or include a printed circuit board. The sensor support thus takes the form of a plate that carries electronic components. The Hall effect sensor can then be attached to the side of the printed circuit board carrying the electronic components and positioned opposite the brush holder. For example, the printed circuit board can be slidably inserted into a housing mounted on the brush holder.

[0030] Advantageously, the printed circuit board may include at least one microprocessor or microcontroller for analyzing data supplied by the Hall effect sensor. The current sensor device may then also include a connection member arranged to collect and transmit the data analyzed by the at least one microprocessor or microcontroller to a data management system.

[0031] Advantageously, to facilitate installation of the concentrator, the concentrator can also preferably be installed without tools and / or removably mounted on the brush holder. For example, the concentrator can be attached to the brush holder by means of a support element attached to the brush holder, particularly without tools and / or removably attached. The support element can also be arranged to protect the concentrator.

[0032] For quick installation, the current sensor device may include at least one of the following features:

[0033] - The brush holder may define at least one retaining member, which cooperates with a retaining member of at least one element selected from the housing, concentrator, and support element.

[0034] - The housing may define at least one retaining member, which cooperates with a retaining member of at least one element selected from the concentrator and the support element.

[0035] - The support element may define at least one retaining member, which cooperates with a retaining member selected from at least one element of the brush retainer, housing and concentrator.

[0036] In particular, these retaining members can be arranged to prevent relative movement of the parts they retain, at least in the longitudinal direction or even in all directions in space.

[0037] These retaining members can be selected from stops, housings, orifices, convex members, and concave members that cooperate with edges or protrusions, element portions, concave members, and convex members, respectively. Convex members can include fingers, lugs, tongues, screws, pins, or the like. Concave members can include orifices, slots, tracks, or the like.

[0038] Advantageously, the length of the concentrator in the longitudinal direction represents 50% or less of the length of the brush holder, optionally starting from the distal end of the brush holder, particularly 40% or less, 30% or less, or 25% or less.

[0039] Advantageously, to improve the efficiency of the concentrator, the length of the concentrator in the longitudinal direction can be equal to or greater than the corresponding length of the Hall effect sensor, preferably at least equal to that length. Optionally, for optimal efficiency, the Hall effect sensor can be located in at least one intermediate plane relative to the concentrator, the intermediate plane being selected from an intermediate plane parallel to the longitudinal direction and an intermediate plane perpendicular to the longitudinal direction.

[0040] The magnetic field concentration and protection functions of the concentrator can be achieved by any suitable material, especially ferromagnetic material, which can optionally have a specific structure, such as a laminated structure or any other suitable structure.

[0041] Advantageously, the concentrator can be made of ferromagnetic material.

[0042] Advantageously, the current sensor device may include at least one additional sensor arranged to measure at least one parameter associated with the state of the brush. This parameter may be selected, for example, from parametric characteristics of wear on the brush, brush temperature, a parameter representing vibration experienced by the brush, or a parameter representing the voltage drop between the brush and the rotating movable surface. The one or more additional sensors may be secured to a brush holder, a sensor support, or a housing that receives the sensor support.

[0043] The present invention also relates to an assembly comprising a current sensor device as described above and a brush slidably received in the longitudinal direction within a housing of a brush holder, such that one end of the brush intended to brush against a rotating movable surface protrudes from the brush holder at a distal end of the brush holder.

[0044] Another object of the present invention is a rotary motor including at least one current sensor device according to the present invention.

[0045] Specifically, the rotary motor may include a plurality of brushes, and each brush is slidably received in the longitudinal direction within the housing of the brush holder of the current sensor device, such that one end of the brush intended to slide against the rotating movable surface of the motor protrudes from the brush holder at the distal end of the brush holder.

[0046] The present invention also relates to a method for assembling a current sensor device for monitoring the current of a brush, particularly as described above, the method comprising:

[0047] - A brush holder is provided, extending longitudinally between a distal and a proximal end and defining a through-house, the through-house intended to slidably receive a brush in the longitudinal direction, such that one end of the brush intended to slide against a rotationally movable surface protrudes from the brush holder at the distal end of the brush holder.

[0048] - A concentrator will be mounted on the brush holder to concentrate the magnetic field within a concentrated magnetic field region and protect that region from external magnetic fields, such that when the brush is received within the housing of the brush holder, particularly around at least a portion of the brush in a plane perpendicular to the longitudinal direction, the magnetic field generated by the current passing through the brush received in the housing of the brush holder will be concentrated by the concentrator within the concentrated magnetic field region.

[0049] - A Hall effect sensor, arranged to detect the magnetic field, is installed on the brush holder at a location within the concentrated magnetic field region in order to measure a value representing the intensity of the current passing through the brush.

[0050] In particular, the present invention is not limited to a specific order of steps for installing the concentrator and the Hall effect sensor.

[0051] Advantageously, the mounting of the Hall effect sensor may include:

[0052] - Attach the Hall effect sensor to the sensor support.

[0053] - Install the sensor support inside the housing.

[0054] - Mount the housing onto the brush holder.

[0055] Specifically, the sensor support can be installed inside the housing without tools and / or removably, and / or the housing can be installed on the brush holder without tools and / or removably.

[0056] The invention will now be described with reference to the accompanying non-limiting drawings, in which:

[0057] Figure 1 This is a perspective view of a current sensor device for receiving brushes according to an embodiment.

[0058] Figure 2 It is installed in Figure 1 An exploded perspective view of the components on the brush holder of the current sensor device.

[0059] Figure 3 yes Figure 1 A schematic diagram of the cross-section of one end of the current sensor device.

[0060] Figure 4This is a side view of the cross-section of the concentrator and the Hall effect sensor.

[0061] Figure 5 yes Figure 1 A perspective view of the brush holder of a current sensor device.

[0062] Figure 6 It is similar to Figure 5 The view also shows the housing and concentrator in their pre-installed position.

[0063] Figure 7 Similar to placing the concentrator and its supporting elements Figure 6 The view.

[0064] Figure 8 It is similar to Figure 7 The view shows the housing in its mounting position.

[0065] Figure 9 The electronic architecture of a rotating machine and a current sensor device mounted on the rotating machine is schematically shown.

[0066] Figure 10 This is a perspective view of the brush holder of a current sensor device according to a variant embodiment.

[0067] Figure 11 It is similar to Figure 10 The view also shows the housing in its pre-installed position.

[0068] Figure 12 It is similar to Figure 11 The view shows the housing in its mounting position after the concentrator and its supporting elements have been placed.

[0069] In the attached diagram, reference frames X, Y, and Z are orthogonal reference frames.

[0070] Reference Figures 1 to 8 The present invention describes a current sensor device 10 for monitoring the current passing through the brush 1 in one embodiment of the invention.

[0071] The current sensor device 10 includes:

[0072] - Brush holder 12

[0073] - Hall effect sensor 14, which is arranged to detect magnetic fields.

[0074] - Concentrator 16, which is arranged to concentrate the magnetic field within a concentrated magnetic field region and protect the region from the influence of external magnetic fields.

[0075] Brush holder 12 extends longitudinally (corresponding to axis z in the figures) between distal end 12a and proximal end 12b. Brush holder 12 defines a through-house 120 intended to slidably receive brush 1 in the longitudinal direction, such that the distal end 1a of the brush, intended to slide against a rotationally movable surface, protrudes from brush holder 12 at distal end 12a. Figure 1 As shown. Therefore, the housing 120 also extends in the longitudinal direction z. Generally, the longitudinal direction of the brush holder 12 is consistent with the longitudinal direction of the brush 12 received within the housing 120.

[0076] Generally, the distal end 1a of the brush 1 protrudes a few millimeters from the distal end 12a of the brush holder 12 along the longitudinal direction z. Typically, the brush holder 12 is made of a thermally conductive material with good mechanical strength, such as brass, stainless steel, copper-aluminum alloy, or any other suitable material.

[0077] Typically, the brush 1 has a parallelepiped shape, as does the housing 120 that receives the brush 1. The housing 120 is generally defined by the walls of the brush holder, which are four walls 121, 122, 123, and 124 extending parallel to the longitudinal direction z.

[0078] According to the invention, a concentrator 16 is mounted on a brush holder 12 such that, when the brush 1 is received in the brush holder 12, it surrounds at least a portion of the brush 1, such that the magnetic field generated by the current passing through the brush is concentrated by the concentrator into a concentrated magnetic field region 160. The concentrated magnetic field region 160 specifically corresponds to the region located between the walls forming the concentrator. Therefore, the concentrator 16, particularly in a plane perpendicular to the longitudinal direction z of the brush holder 12, at least partially surrounds the housing 120 defined by the brush holder 12.

[0079] In the illustrated embodiment, the concentrator 16 has a U-shape in a plane extending perpendicular to the longitudinal direction of the brush holder. Therefore, three walls 161, 162, and 163 are formed extending parallel to the longitudinal direction z, wherein two walls 161 and 163 forming the U-shaped wings are parallel to each other and connected by a third wall 162. Thus, the concentrator 16 surrounds three of the four faces of the brush holder, and the concentrated magnetic field region 160 extends between the three walls 161 and 163. The concentrator 16 is formed, for example, from a material plate having a rectangular shape folded into a U-shape.

[0080] This U-shape has the advantage of being easy to manufacture and assemble on the brush holder. However, the invention is not limited to this embodiment. In particular, it is conceivable that a concentrator or U-shaped concentrator completely surrounds the brush holder in a plane perpendicular to the longitudinal direction, with the free ends of its wings curving towards each other parallel to the wall 124, thus having a C-like shape.

[0081] The concentrator 16 is made of a ferromagnetic material in a conventional manner. Contemplated ferromagnetic materials include iron, nickel, SiFe, NiFe, or any other ferromagnetic material. The concentrator can be formed, for example, from a sheet of metal or from a stack of metal sheets. The concentrator can be formed, for example, from multiple stacked iron and nickel sheets.

[0082] Those skilled in the art will be able to determine the thickness of the concentrator in a conventional manner based on the magnitude of the current flowing through the brush.

[0083] Generally, the concentrator 16 is preferably positioned abutting against the brush holder, for example, against the walls 121 to 124 of the housing 120 defining the exterior of the brush holder. This minimizes the space between the brush holder and the concentrator, allowing the concentrator to be positioned as close as possible to the Hall effect sensor and improving the concentration of the magnetic field. Those skilled in the art will be able to provide a mounting clearance between the concentrator and the brush holder. In embodiments not shown, the concentrator may abut against the walls 121 to 124 of the housing 120 defining the interior of the brush holder. The concentrator then at least partially defines the housing 120.

[0084] According to the present invention, a Hall effect sensor is mounted on the brush holder 12 at a position within the concentrated magnetic field region 160 in order to measure a value representing the intensity of the current flowing through the brush 1.

[0085] Hall effect sensors are sensitive to magnetic fields generated by the flow of current. A Hall effect sensor converts the generated magnetic field into a voltage proportional to the magnetic field. The sensor's output can be linearly related to the magnetic field, and since the magnetic field is linearly related to the current in the conductor, the output voltage will provide a linear voltage proportional to the current. For sensors with non-linear outputs, the current can be determined graphically or by formulas, for example, integrated into a microprocessor microcontroller. The operation of this type of sensor is well known and will not be described in detail further.

[0086] Conventional Hall effect sensors detect magnetic flux perpendicular to their surface, which makes it impossible to mount them very close to a conductor in which the current to be measured flows.

[0087] While such a sensor could be envisioned in this invention, it would be relatively bulky and not very sensitive. Preferably, a Hall effect sensor sensitive to magnetic fields extending parallel to its surface is used. This type of Hall effect sensor is more sensitive than conventional Hall effect sensors and can be mounted as close as possible to the conductor in which the current to be measured flows, thus improving the sensor's sensitivity. Advantageously, a Hall effect sensor with an integrated magnetic concentrator can be used; in other words, a Hall effect sensor using... Hall effect sensors using integrated magnetic concentrator technology. This type of sensor is manufactured using standard CMOS technology and features an additional ferromagnetic layer. Its characteristics include a weak (very soft) coercive field and high permeability, enabling the magnetic field concentrator function. This type of sensor also has the advantage of being able to measure alternating current (AC) or direct current (DC).

[0088] To improve measurement accuracy, the concentrator 16 and the Hall effect sensor 14 are advantageously located closer to the distal end 12a of the brush holder 12 than to the proximal end 12b. In a preferred embodiment, as shown, the concentrator 16 is attached, for example, along the edge of the walls 121 to 123 of the brush holder defining the housing 120 at the distal end 12a of the brush holder 12.

[0089] Generally, advantageously, the portion of the brush holder 12 surrounded by the concentrator 16 extends longitudinally in length L, which represents 50% or less of the length of the brush holder, particularly starting from the distal end 12a of the brush holder 12. This length L corresponds to the dimension of the concentrator 16 in the longitudinal direction z. However, advantageously, the length L of the concentrator 16 in the longitudinal direction is at least equal to, and preferably greater than, the length l of the Hall effect sensor 14, for example, 1.5 to 3 times greater than the length of the sensor 14. Thus, the length L of the concentrator can be selected within a range, the minimum of which is as previously defined, and the maximum of which represents 50%, 40%, 30%, 25%, or less of the length of the brush holder.

[0090] Sensor 14 will preferably be positioned within the concentrated magnetic field region, at a midpoint relative to the concentrator in both a plane perpendicular to the longitudinal direction and a plane parallel to the longitudinal direction. In other words, as... Figure 3 and Figure 4 As can be seen, the Hall effect sensor is located in the middle of the interval e between the walls 161 and 163 across the concentrator and in the middle of the longitudinal direction z along the concentrator.

[0091] In the illustrated embodiment, it should be noted that the Hall effect sensor 14 is located between the U-shaped wings, on the same side as its opening, at a very short distance from the U-shaped wings. The Hall effect sensor can be positioned closer to the opening, as long as the sensor remains within the area 160 defined by the walls 161 to 163 of the concentrator. The Hall effect sensor will preferably be positioned as close as possible to the brush holder 12 to obtain better measurement accuracy, but a mounting gap can be provided between the brush holder 12 and the Hall effect sensor.

[0092] exist Figures 1 to 8 and Figures 10 to 12In the example shown, the Hall effect sensor 14 is attached to a sensor support 18 located within a housing 20 mounted on the brush holder 12. The housing 20 protects the Hall effect sensor 14, or even the sensor support 18, from external environmental influences. This mounting is implemented such that the Hall effect sensor is removably mounted on the brush holder.

[0093] exist Figures 1 to 8 In the example shown, Hall effect sensor 14 is attached to sensor support 18, sensor support 18 is attached to housing 20, housing 20 is fitted onto brush holder 12 by means of lugs 201, the lugs 201 being inserted into corresponding orifices 125 in the brush holder. These lugs 201 engage with opposing walls of brush holder 12. The lugs 201 and orifices 125 thus form a retaining member within the meaning of this invention.

[0094] The sensor support 18 is mounted within the housing 20, for example, by insertion, interlocking, overmolding, gluing, or a combination of these methods. In particular, overmolding has the advantage of better protecting the sensor 14 and the sensor support 18 from the external environment of the housing 20.

[0095] It should be noted that the surface of the housing 20 assembled on the brush holder is not closed, and therefore the housing is in the form of a half-shell. Thus, when the housing is mounted on the brush holder, the sensor support 18 is located opposite the wall 124 of the brush holder, which closes the housing 20.

[0096] This invention is not limited to this method of removably attaching the housing 20 to the brush holder 12, and any other removable or non-removable interlocking mechanism that functions through the cooperation of convex and concave members is conceivable. Thus, the housing can be slidably mounted on the brush holder, or simultaneously slidably mounted to components interlocked on the brush holder by engaging fingers or lugs with orifices of corresponding shapes. It is also conceivable to removably mount the sensor support within the housing by interlocking, sliding, and / or snap-fitting.

[0097] therefore, Figures 10 to 12 It shows the relationship with Figures 1 to 8 The only difference between the embodiments described is the method of removably attaching the housing 20 to the brush holder 12, and therefore the same elements will be designated by the same reference numerals. In this embodiment, the brush holder 12 has two guides 135 (with L-shaped cross-sections) positioned facing each other on its wall 124. Figure 10In other words, each of these guides 135 defines a groove or slot 136 with the wall 124, thus forming a guide track with the wall 124. These guides 135 extend in the longitudinal direction z over a portion of the height of the brush holder 12. The housing 20 itself has two protruding guide portions 231 on opposing surfaces 210, 211, which also extend parallel to the z direction and are received within each guide 135 in a sliding manner similar to a slider. In the example shown, these guide portions 231 are in the form of tongues. Furthermore, the guide portions 231 do not extend over the entire height of the housing 20 for ease of installation. However, the invention is not limited to the form or length of the guides and guide portions, as long as the guides and guide portions can cooperate with each other, in this case, translation. Therefore, within the meaning of the invention, the guide portions and guides form convex and concave retaining members, respectively. These retaining members cooperate here by sliding to achieve removable installation.

[0098] It should be noted that the guide 135 can be fixed to the housing 20, and the guide portion 231 can be fixed to the brush holder.

[0099] A retaining member may also be provided to prevent any translational movement between the housing 20 and the brush holder 12. This retaining member may be, for example, a screw or multiple screws inserted, in a direction perpendicular to the translational direction, via at least one of the guide and / or guide portion. The screw may simply abut against the housing 20 or the tongue 231 for close contact, or be inserted into an aperture in the housing 20, such as a simple slot (or discontinuous) in the guide portion, or through a circular aperture 137 of the guide 135. Figure 10 The retaining member can be a screw with a standard screw head, such as compatible with flathead or Phillips head screwdrivers, or have a specific form that works with a particular screwdriver. Optionally, a small amount of glue can be added to prevent the screw from unscrewing in the presence of vibration. The retaining member can also be a pin-type retaining member held in a blocking position within the hole by a spring. This type of retaining member can be actuated by a right-angle rotary mechanism.

[0100] Finally, you can Figures 10 to 12 The implementation methods and Figures 1 to 8 The combination of implementation methods.

[0101] The concentrator 16 is held on the brush holder 12 by means of a support element 22. This serves both to support and protect the concentrator 16. In the example, the support element 22 is in the form of a frame defined by walls 221, 222, 223, 224, which completely surround the brush holder 12 in a plane perpendicular to the longitudinal direction and extend parallel to the longitudinal direction z. The walls 221, 222, 223, 224 also surround the concentrator 16 and the housing 20. For good retention and minimal size, the support element 22 matches the external shape of the brush holder 12 equipped with the concentrator and housing. The length of the support element 22 in the longitudinal direction is preferably at least equal to the length L of the concentrator for better protection, but smaller sizes are conceivable as long as the support element 22 can ensure retention of the concentrator 16. Similar to the housing 20, the support element 22 is preferably made of a polymer material. The support element 22 includes an internal stop 220 for holding the concentrator in the longitudinal direction z. Therefore, these stops protrude from the frame perpendicular to the longitudinal direction z by a length corresponding to no more than the corresponding dimension of the concentrator. In this way, these stops will not protrude into the housing 120 of the brush holder when the support element is mounted on the housing 120 of the brush holder, and will not interfere with the sliding of the brush 1 within the housing.

[0102] In a preferred embodiment, the concentrator 16 may also be removably mounted on the brush holder 12, as shown in the example. For this purpose, the concentrator 16 is mounted within a support element 22, which is removably attached to the brush holder 12.

[0103] This removable mounting can be achieved through the cooperation of retaining members between the brush holder 12 and the concentrator 16 and / or its support element 22, between the housing 20 and the concentrator 16 and / or its support element 22, between the support element 22 and the housing 20, the brush holder 12, the concentrator 16, or two or three of these elements.

[0104] These retaining members may be selected from stops or protrusions that cooperate with the edge, tongue or similar of another element, housings or hollows that receive part or all of another element, and convex members, such as fingers or lugs, that cooperate with concave elements such as orifices or tracks.

[0105] Therefore, in this example, the brush holder 12 has a housing 126 at its distal end 12a that receives the concentrator 16 on the outer side of its walls 121 to 123: the concentrator 16 can be fitted onto the brush holder 12 in the longitudinal direction z up to the end of the housing 126. The housing 20 has a stop 202 (here, rim) at its end that cooperates with the edge of the support element 22, the stop 202 cooperating with the edge of the wall 224 of the support element 22.

[0106] In the described example, the housing 20 can therefore be easily mounted on the brush holder 12, particularly without tools, and the housing 20 can be reversibly mounted. This makes it possible to equip the brush holder and / or replace a defective housing after it has been put into operation. However, it is conceivable to fix the housing to the brush holder, but this is not preferred, or even to integrate the housing with the brush holder or to integrate the sensor support directly with the brush holder.

[0107] Now refer to Figures 5 to 8 and Figures 10 to 12 This describes the assembly of a current sensor device for monitoring brush current. First, a brush holder 12 as previously described is provided.

[0108] Next, the Hall effect sensor 14 is mounted on the brush holder 12. For this purpose, the first step is to attach the Hall effect sensor 14 to the sensor support 18, and then mount the sensor support 18 within the housing 20. The sensor support 18 can be held in the housing by interlocking, by sliding and / or by snap-fitting, and / or by means of a polymer material that completely or partially covers it. The housing 20 thus assembled is then secured to the brush holder 12. In this example, the housing 20 is initially held... Figure 6 or Figure 11 The pre-installation position shown indicates that the housing 20 is abutted against the wall 124 of the housing in a position that allows the support element 22 of the concentrator 16 to be placed around the housing and the brush holder 12. In the example, this is the following position ( Figure 6 In this position, the lug 201 of the housing 20 is located in the z-direction below the orifice 125 into which the lug 201 of the brush holder must be inserted, or in the following position ( Figure 11 In this position, the guide portion 231 of the housing 20 is located in the z-direction below the guide member 135 of the brush holder, into which the guide portion 231 must be inserted.

[0109] Next, the concentrator 16 is mounted on the brush holder 12 so as to surround the housing 120 into which the brush holder is inserted (see...). Figure 6 At least a portion of the brush in the brush holder 12. For this purpose, a U-shaped concentrator is mounted on the brush holder 12 in the longitudinal direction z via the distal end 12a of the brush holder 12. Here, the concentrator 16 is received in a housing 126 provided on the outer surfaces of the walls 121 to 123 of the brush holder 12, and abuts against the bottom of the housing. Figure 5The visible step 127 is adjacent to it. Then, the support element 22 can be placed in place: the support element 22 is first tilted to pass through the stop 202 of the housing, and then straightened so that it can be assembled longitudinally onto the concentrator and the housing 20, as shown. Figure 7 As shown.

[0110] Alternatively, for easier installation, the concentrator 16 can be positioned within the support element 22, and the support element 22 can then be positioned around the brush holder 12 and the housing 20 by tilting and moving in the longitudinal direction z, in order to achieve the installation 7 shown in the figure, as described above.

[0111] Next, the housing 20 moves longitudinally until its stop 202 engages with the support element 22, holding the support element 22 in place in the longitudinal direction z (see...). Figure 8 and Figure 12 Naturally, the stop 202 can also be provided on the brush holder, for example, on the edge of its wall 122.

[0112] Naturally, the present invention is not limited to a specific order in which the various components are installed, which may vary depending on the configuration of these components and retaining members.

[0113] The sensor support 18 is an integrated circuit board, which includes at least one microprocessor or microcontroller (not shown) for analyzing data supplied by the Hall effect sensor. The sensor support 18 will preferably be positioned on the surface of the integrated circuit board that carries the electronic components, which is positioned to face the brush holder 12.

[0114] The current sensor device 10 advantageously includes a connection member 24, which is arranged to collect and transmit data analyzed by the at least one microprocessor or microcontroller to the data management system 26. Specifically, the microprocessor or microcontroller processes the signal received by the Hall effect sensor using mathematical functions such as quadratic averaging (RMS, root mean square), and transmits the processed signal to the connection member 24, which collects data received from the current sensor device 10 connected thereto and transmits the received data to the data management system 26. The data management system 26 can allow for the acquisition, processing, and display of the received data. The data management system 26 may include one or more processors and display devices. The data management system 26 may be, for example, a computer.

[0115] The connection component 24, such as a gateway, can be arranged for wireless or cable transmission to the data management system 26. The connection component 24 also allows the current sensor device 10 to be connected to a power supply 28 that powers a microprocessor or microcontroller and optionally a Hall effect sensor. The connection component 24, the data management system 26, and the power supply 28 can be shared for multiple current sensor devices of the rotating motor.

[0116] The described current sensor device 10 can be integrated into the mounting component 300 of the rotating motor 30. This mounting component can be a stator, a mounting coil, a mounting device electrically connected to the brush cable, etc. (Displayed) Figure 9 The fixed component 300 shown in the middle section includes ring portions 301, each ring portion supporting a plurality of brush holders 10 and current connectors 302. The fixed component 300 generally surrounds a rotating component (not shown) of the motor 30. The rotating component may be, for example, a rotating shaft, a rotating ring collector, etc., and has the same axis as the axis of the ring portion 301.

[0117] The present invention and its embodiments have the following advantages:

[0118] 1) The Hall sensor is protected from external magnetic sources and is non-invasive, making it possible to measure the current through the brushes very effectively;

[0119] 2) It can measure high currents (high amplitude) with linear response up to 600A.

[0120] 3) When measuring current at a remote location, where the current flows radially, the total current passing through the cross-section of the brush is measured.

[0121] 4) The current sensor device is compact.

[0122] 5) The current sensor device is easy to install / remove, especially without tools.

[0123] Using the current sensor device according to the invention, currents up to 600A can be measured, with a maximum difference of ±30A, which corresponds to an accuracy of ±5% or even ±2%. Higher currents can be measured by increasing the thickness of the concentrator.

[0124] The current sensor device may also include one or more other sensors 32 (in Figure 2 and Figure 9 (Illustrated schematically) This allows for the measurement of at least one parameter associated with the state of the brush. Therefore, the complete performance of the brush can be monitored in real time.

[0125] This parameter can be selected from the wear characteristics of the brush, such as brush length or brush position, brush temperature, parameters representing the vibration experienced by the brush, or parameters representing the voltage drop between the brush and the rotating movable surface.

[0126] Brush wear can be determined using position sensors such as reed contacts. A reed contact (or reed switch or flexible leaf switch) is a magnetic switch consisting of two leaflets made of magnetic material sealed within a glass tube containing a neutral gas. The leaflets slightly overlap at the contact within the glass, with a gap of a few hundredths of a millimeter (air gap) between them. When the switch is placed in a magnetic field, the leaflets are affected and magnetized, attracting each other until they make contact. Repression of the magnetic field causes the leaflets to separate. A magnetic field can be generated by bringing near a magnet fastened to the brush. This magnet can be located at one end of the brush or at any other location within the brush corresponding to a specific wear location.

[0127] Brush wear can also be determined by position sensors such as Hall effect sensors, which interact with magnetic fields or by sensing elements such as magnets or inductive reactors disposed within the brush.

[0128] Such position sensors can be attached to brush holders or sensor supports.

[0129] Vibration can be detected by means of an accelerometer attached to the brush, brush holder, sensor support, or pressure system adjacent to the brush to keep the brush in contact with the rotating movable surface.

[0130] The voltage drop between the brush and the rotating movable surface can be detected by using two cables connected to a voltmeter.

[0131] Temperature sensors, such as thermocouples, can also be attached to brush holders or sensor supports.

[0132] Each of these sensors is advantageously connected to the data management system, particularly via connecting members.

Claims

1. A current sensor device (10) for monitoring the current passing through a brush (1), the current sensor device (10) comprising: A brush holder (12) extends longitudinally between a distal end (12a) and a proximal end (12b) and defines a through housing (120) intended to slidably receive a brush in the longitudinal direction, such that one end of the brush intended to brush against a rotationally movable surface protrudes from the brush holder (12) at the distal end of the brush holder (12). A Hall effect sensor (14) is arranged to detect a magnetic field. A concentrator (16) is arranged to concentrate the magnetic field within a concentrated magnetic field region (160) and protect the region (160) from the influence of external magnetic fields. in, The concentrator (16) is mounted on the brush holder (12) so as to surround at least a portion of the brush when the brush is received within the housing (120) of the brush holder (12). The Hall effect sensor (14) is mounted on the brush holder (12) at a location within the concentrated magnetic field region (160) so as to measure a value representing the intensity of the current passing through the brush when the brush is received in the housing (120) of the brush holder (12).

2. The current sensor device (10) according to claim 1, wherein, The concentrator (16) and the Hall effect sensor (14) are located in the longitudinal direction closer to the distal end (12a) of the brush holder (12) than to the proximal end (12b).

3. The current sensor device (10) according to claim 1, wherein, The housing (120) has a quadrilateral cross-section in a plane extending perpendicular to the longitudinal direction of the brush holder (12), and when the brush is received within the housing (120), the concentrator (16) surrounds the brush on at least three sides of the quadrilateral.

4. The current sensor device (10) according to claim 1, wherein, The Hall effect sensor (14) is attached to a sensor support (18) located within a housing (20) mounted on the brush holder (12).

5. The current sensor device (10) according to claim 4, wherein, At least one element selected from the housing (20) and the sensor support (18) is removably mounted.

6. The current sensor device (10) according to claim 4, wherein, The sensor support (18) is an integrated circuit board or includes an integrated circuit board, which includes at least one microprocessor or microcontroller for analyzing data supplied by the Hall effect sensor (14).

7. The current sensor device (10) according to claim 6 further includes a connecting member arranged to collect and transmit data analyzed by the at least one microprocessor or microcontroller to a data management system.

8. The current sensor device (10) according to any one of claims 1 to 7, wherein, The concentrator (16) is attached to the brush holder (12) by means of a support element (22) attached to the brush holder (12).

9. The current sensor device (10) according to claim 8, characterized in that: At least one of them: The brush holder (12) defines at least one retaining member (125, 126; 135) that cooperates with a retaining member (161-163) selected from at least one element of the concentrator (16) and the support element (22). The support element (22) defines at least one retaining member (220) that cooperates with a retaining member (161-163) selected from at least one element of the brush holder (12) and the concentrator (16).

10. The current sensor device (10) according to any one of claims 4 to 7, wherein, The brush holder (12) defines at least one retaining member (135) that cooperates with the retaining member (231) of the housing (20).

11. The current sensor device (10) according to any one of claims 4 to 7, further comprising a support element (22) attached to the brush holder (12), the concentrator (16) being attached to the brush holder (12) by means of the support element (22), and characterized in that At least one of the following: The housing (20) defines at least one retaining member (202) that cooperates with a retaining member (224) selected from at least one element of the concentrator (16) and the support element (22). The support element (22) defines at least one retaining member (220) that cooperates with the retaining member (163) of the housing (20).

12. The current sensor device (10) according to any one of claims 1 to 7, wherein, The length of the concentrator (16) in the longitudinal direction represents 50% or less of the length of the brush holder (12).

13. The current sensor device (10) according to claim 12, wherein, 50% or less of the length of the brush holder (12) is measured from the distal end of the brush holder (12).

14. The current sensor device (10) according to any one of claims 1 to 7, wherein, The length of the concentrator (16) in the longitudinal direction is equal to or greater than the corresponding length of the Hall effect sensor (14).

15. The current sensor device (10) according to claim 14, wherein, The Hall effect sensor (14) is located in at least one intermediate plane relative to the concentrator (16), the intermediate plane being selected from an intermediate plane parallel to the longitudinal direction and an intermediate plane perpendicular to the longitudinal direction.

16. The current sensor device (10) according to any one of claims 1 to 7, wherein, The concentrator (16) is made of ferromagnetic material.

17. The current sensor device (10) according to any one of claims 1 to 7, comprising at least one other sensor arranged to measure at least one parameter associated with the state of the brush.

18. The current sensor device (10) according to claim 1, wherein, The at least portion of the brush is located in a plane perpendicular to the longitudinal direction.

19. A rotary motor (30) comprising at least one current sensor device (10) according to any one of claims 1 to 18.

20. A method for assembling a current sensor device for monitoring the current of a brush, the method comprising: A brush holder is provided, extending longitudinally between a distal and a proximal end and defining a through-shell, the through-shell intended to slidably receive a brush along the longitudinal direction, such that one end of the brush intended to slide against a rotationally movable surface protrudes from the brush holder at its distal end. The method further includes: A concentrator, configured to focus the magnetic field within a concentrated magnetic field region and protect that region from external magnetic fields, is mounted on the brush holder such that, when the brush is received within the housing of the brush holder, at least a portion of the brush is surrounded by the concentrator, such that the magnetic field generated by the current flowing through the brush received within the housing of the brush holder is focused by the concentrator into the concentrated magnetic field region. A Hall effect sensor, arranged to detect the magnetic field, is mounted on the brush holder at a location within the concentrated magnetic field region in order to measure a value representing the intensity of the current passing through the brush.

21. The method according to claim 20, wherein, The installation of the Hall effect sensor includes: The Hall effect sensor is attached to the sensor support. The sensor support is installed inside the housing. The housing is mounted on the brush holder.

22. The method according to claim 20, wherein, The at least portion of the brush is located in a plane perpendicular to the longitudinal direction.

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