Customized magnetic core current sensor based on long magnetic sheet rolling lamination and manufacturing method

Abstract

The invention discloses a customized magnetic core current sensor based on long magnetic sheet rolling lamination and a manufacturing method, and belongs to the technical field of current sensing. The current sensor comprises a magnetic core assembly, a coil assembly and a fixing assembly, the magnetic core assembly is of an annular structure formed by winding at least one long magnetic sheet with the fixed length for at least one layer along a preset inner diameter, the number of winding layers is 1-N, N is a natural number larger than 1, the coil assembly is wound on the outer side of the magnetic core assembly, and the fixing assembly is fixed on the coil assembly. The coil assembly is formed by winding an enameled wire, a copper foil or a flexible printed circuit, and the fixing assembly is used for fixing the winding form of the magnetic core assembly. Rapid and low-cost customization of the inner diameter of the magnetic core is achieved, mold opening is not needed, conductors with different perimeters are matched through long magnetic sheet cutting and rolling, the method is particularly suitable for large-size scenes, magnetic circuit continuity is good, splicing air gaps are avoided, measurement precision and consistency are improved, the structure is stable, the technology is simple, production cost is reduced, the delivery cycle is shortened, and the production efficiency is improved. And the application flexibility of the current sensor is expanded.

Description

Technical Field

[0001] This invention relates to the field of current sensing technology, specifically to a customized magnetic core current sensor based on long magnetic sheet roll-up and stacking, and its manufacturing method. Background Technology

[0002] Traditional current sensor cores are typically formed using pressing, sintering, die casting, or mold processing, resulting in fixed and non-adjustable core dimensions. When dealing with conductors of varying sizes (especially large circumferences), it is usually necessary to redesign and manufacture molds for different inner diameters, leading to high costs, long production cycles, and poor flexibility. While existing technologies employ small magnetic sheets spliced ​​together to form magnetic rings, this method is insufficient for large objects with circumferences exceeding 1 meter. The large number of splices and discontinuous magnetic circuits at the joints result in poor magnetic performance consistency, increased magnetic losses, and decreased measurement accuracy. Therefore, there is an urgent need for a core structure and manufacturing method that requires no molds, allows for rapid customization, is suitable for large circumference applications, and provides good magnetic circuit continuity, enabling a low-cost and highly adaptable current sensing solution.

[0003] To address the aforementioned issues, there is an urgent need for a customized magnetic core current sensor based on long magnetic sheet roll-up and stacking, and its fabrication method, to solve the problems existing in traditional methods. Summary of the Invention

[0004] The purpose of this invention is to provide a customized magnetic core current sensor based on long magnetic sheet roll stacking and its manufacturing method. This invention enables rapid and low-cost customization of the magnetic core inner diameter without the need for mold making. By cutting and rolling long magnetic sheets, it can be adapted to conductors of different circumferences, making it particularly suitable for large-size applications. It has good magnetic circuit continuity, avoids splicing air gaps, improves measurement accuracy and consistency, has a stable structure, and a simple process. This reduces production costs and delivery time, and expands the application flexibility of current sensors.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A customized magnetic core current sensor based on long magnetic sheet roll stacking includes: a magnetic core assembly, a coil assembly, and a fixing assembly. The magnetic core assembly is a ring structure formed by winding at least one layer of at least one long magnetic sheet of a fixed length along a predetermined inner diameter. The number of layers is 1 to N, where N is a natural number greater than 1. The long magnetic sheet is a flexible or rollable strip magnetic material, such as nanocrystalline soft magnetic tape, amorphous alloy soft magnetic tape, silicon steel tape, permalloy tape, iron-nickel alloy tape, high permeability flexible ferrite sheet, ferrite composite sheet, magnetic powder filled composite sheet, and flexible sheet formed by combining soft magnetic powder with resin, rubber, or polymer. The coil assembly is wound around the outside of the magnetic core assembly. The coil assembly is made of enameled wire, copper foil, or flexible printed circuit. The fixing assembly is used to fix the roll shape of the magnetic core assembly.

[0006] Furthermore, the fixing component uses at least one of the following methods to fix the rolled shape of the magnetic core assembly: adhesive fixing, binding fixing, heat shrink tubing fixing, and mechanical clamping fixing.

[0007] Furthermore, an insulating layer is provided on the outside of the magnetic core assembly to prevent short circuits or wear between the magnetic core assembly and the coil assembly. The insulating layer includes polyimide tape, PET insulating film, or fiberglass insulating paper.

[0008] Furthermore, the customized magnetic core current sensor also includes a hinged housing for encapsulating the magnetic core assembly and the coil assembly.

[0009] This invention also provides a method for fabricating a customized magnetic core current sensor based on long magnetic sheet roll-up, for realizing the above-mentioned customized magnetic core current sensor based on long magnetic sheet roll-up, comprising: Step 1: Obtain the circumference or diameter of the conductor being measured; Step 2: Determine the inner diameter of the magnetic core based on its circumference or diameter; Step 3: Calculate the cutting length of the long magnetic sheet based on the inner diameter of the magnetic core, the thickness of the magnetic sheet, and the number of layers rolled; Step 4: Cut the long magnetic sheet to the required length to obtain the magnetic sheet to be rolled. Step 5: Roll the magnetic sheet to be rolled into a ring-shaped stacked structure that matches the inner diameter of the magnetic core to obtain the magnetic core assembly; Step 6: Secure the magnetic core assembly to prevent springback and interlayer misalignment; Step 7: Wind the coil assembly around the outer periphery of the magnetic core assembly, add an insulation layer between the magnetic core assembly and the coil assembly, and lead out the cable of the coil assembly; Step 8: Package the magnetic core assembly and coil assembly to obtain the finished magnetic core current sensor.

[0010] Furthermore, in step 2, after determining the inner diameter of the magnetic core, a clearance is reserved for installation.

[0011] Furthermore, in step 6, the magnetic core assembly is fixed by means of adhesive bonding, binding, heat shrinking, or clamping.

[0012] In summary, the present invention has at least one of the following beneficial technical effects: 1. Enables low-cost and rapid customization: There is no need to re-mold for different sizes. By simply cutting standard magnetic sheets of different lengths and rolling them, magnetic cores with the required inner diameter can be obtained quickly, which greatly reduces production costs and delivery cycle.

[0013] 2. Suitable for large perimeter and special size scenarios: It is especially suitable for current measurement of large conductors with a perimeter of more than 1 meter, which solves the problems of many seams and poor performance of traditional spliced ​​magnetic cores and expands the application range of current sensors.

[0014] 3. Ensures magnetic circuit continuity and performance consistency: The use of continuous long magnetic sheets avoids air gaps caused by splicing, resulting in good magnetic circuit continuity, low magnetic loss, and improved measurement accuracy and consistency of the sensor.

[0015] 4. Flexible structure and high stability: The laminated structure is fixed by various methods such as gluing, binding, and heat shrinking, which ensures the mechanical stability and shape retention of the magnetic core under complex working conditions.

[0016] 5. Simple manufacturing process and easy to implement: The manufacturing method has clear steps, low equipment requirements, and is easy to standardize and scale up production, and has good industrial promotion value. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural view of the customized magnetic core current sensor of the present invention; Figure 2 This is a schematic flowchart of the method of the present invention; Figure 3 This is a front view of the structure of the customized magnetic core current sensor of the present invention; Figure 4 This is a 3D view of the magnetic core assembly structure; Figure 5 This is a front view of the magnetic core assembly structure.

[0018] Reference numerals: 1. Magnetic core assembly; 2. Coil assembly. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0020] like Figure 1 , Figure 3 As shown, this invention provides a customized magnetic core current sensor based on long magnetic sheet roll-up, comprising: a magnetic core assembly 1, a coil assembly 2, and a fixing assembly, which will be described in detail below: 1. Magnetic core assembly like Figure 4 , Figure 5As shown, the magnetic core assembly 1 is a ring structure formed by winding at least one layer of at least one long magnetic sheet of a fixed length along a predetermined inner diameter. The number of layers is 1 to N, where N is a natural number greater than 1. A positioning mandrel can be used during the winding process to ensure the accuracy of the inner diameter. The long magnetic sheet material may include, but is not limited to: metallic magnetic materials (e.g., nanocrystalline soft magnetic tape, amorphous alloy soft magnetic tape, silicon steel tape, permalloy tape, iron-nickel alloy tape, etc.); non-metallic magnetic materials (e.g., high-permeability flexible ferrite sheets, ferrite composite sheets, etc.); soft magnetic composite materials (e.g., flexible sheets formed by combining soft magnetic powder with resin / rubber / polymer, magnetic powder-filled composite sheets, etc.); and other metallic or non-metallic materials with magnetic properties, or their composite materials or laminates.

[0021] 2. Coil assembly A coil assembly 2 is wound around the outside of the magnetic core assembly 1. The coil assembly 2 can be made of enameled wire, copper foil winding or flexible printed coil. The number of coil turns can be set according to the target sensitivity and frequency band requirements, for example, 1 to 500 turns.

[0022] 3. Fixing components The rolled magnetic core can be fixed in shape by at least one of the following methods: adhesive bonding, binding, heat shrinking, or clamping. These methods can be used individually or in combination to improve structural stability.

[0023] 4. Insulation layer An insulating layer is provided on the outside of the magnetic core assembly 1 to prevent short circuits or wear between the magnetic core assembly 1 and the coil assembly 2. The insulating layer includes polyimide tape, PET insulating film or glass fiber insulating paper, etc.

[0024] 5. Packaging The magnetic core assembly 1 and the coil assembly 2 are encapsulated in a hinged housing.

[0025] like Figure 2 As shown, the present invention also provides a method for fabricating a customized magnetic core current sensor based on long magnetic sheet roll-up, for realizing the above-mentioned customized magnetic core current sensor based on long magnetic sheet roll-up, comprising: Step 1: Obtain the circumference L or diameter D of the conductor being measured; Step 2: Determine the inner diameter of the magnetic core D≈L / π based on the circumference L or diameter D. Here, the circumference L is converted based on the diameter D, and the installation gap Δ is reserved to obtain D'=D+Δ. Step 3: Calculate the cutting length Lc of the long magnetic sheet based on the inner diameter D' of the magnetic core, the thickness t of the magnetic sheet, and the number of layers n. Step 4: Cut the long magnetic sheet according to the cutting length Lc to obtain the magnetic sheet to be rolled; Step 5: Roll the magnetic sheet to be rolled into a ring-shaped stacked structure that matches the inner diameter of the magnetic core to obtain the magnetic core assembly; Step 6: Secure the magnetic core assembly using adhesive, binding, heat shrinking, or clamping methods to prevent springback and interlayer misalignment; Step 7: Wind the coil assembly around the outer periphery of the magnetic core assembly, add an insulation layer between the magnetic core assembly and the coil assembly, and lead out the cable of the coil assembly; Step 8: Package the magnetic core assembly and coil assembly to obtain the finished magnetic core current sensor.

[0026] This invention provides some embodiments, specifically: Example 1: When the circumference of the object being measured is 1 meter, the inner diameter of the magnetic core Din≈0.318 meters. A magnetic sheet of about 1 meter in length is cut and rolled into one layer to form a ring-shaped magnetic core. After fixing, a coil is wound to obtain a current sensor.

[0027] Example 2: When the circumference of the object being measured is 4 meters, the inner diameter of the magnetic core Din≈1.273 meters. A magnetic sheet of about 4 meters in length is cut and rolled into 2 layers to form a ring-shaped magnetic core. After fixing, a coil is wound to obtain a current sensor.

[0028] Example 3: Under the same inner diameter requirement, increasing the number of winding layers n can increase the cross-sectional area of ​​the magnetic core, reduce magnetic resistance, improve sensitivity and response.

[0029] This invention provides an embodiment in which the long magnetic sheet is a flexible or rollable strip-shaped magnetic material, including nanocrystalline soft magnetic tape, amorphous alloy soft magnetic tape, high-permeability flexible ferrite sheet, ferrite composite sheet, magnetic powder-filled composite sheet, and flexible sheet formed by combining soft magnetic powder with resin, rubber, or polymer. The main protective material is a thin ferrite sheet or ferrite powder, with thin film materials bonded to both sides of the core material to form a flexible long magnetic sheet. The ferrite material can be nickel-zinc, manganese-zinc, etc. Its frequency range is 100kHz~40MHz.

[0030] Embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0031] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0032] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0033] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0034] Contents not described in detail in this specification are prior art known to those skilled in the art. It is hereby indicated that the above description is intended to help those skilled in the art understand this invention, but does not limit the scope of protection of this invention. Any equivalent substitutions, modifications, improvements, or simplifications of the above descriptions that do not depart from the essential content of this invention fall within the scope of protection of this invention.

Claims

1. A customized magnetic core current sensor based on long magnetic sheet rolled and stacked layers, characterized in that, include: The magnetic core assembly comprises a magnetic core assembly, a coil assembly, and a fixing assembly. The magnetic core assembly is a ring structure formed by winding at least one layer of at least one long magnetic sheet of a fixed length along a predetermined inner diameter. The number of layers is 1 to N, where N is a natural number greater than 1. The long magnetic sheet is a flexible or rollable strip-shaped magnetic conductive material, and is one of the following: nanocrystalline soft magnetic tape, amorphous alloy soft magnetic tape, silicon steel tape, permalloy tape, iron-nickel alloy tape, high permeability flexible ferrite sheet, ferrite composite sheet, magnetic powder filled composite sheet, and flexible sheet formed by combining soft magnetic powder with resin, rubber, or polymer. The coil assembly is wound around the outside of the magnetic core assembly. The coil assembly is made of enameled wire, copper foil, or flexible printed circuit. The fixing assembly is used to fix the winding shape of the magnetic core assembly.

2. The customized magnetic core current sensor based on long magnetic sheet roll-and-stacking as described in claim 1, characterized in that, The fixing component uses at least one of the following methods to fix the rolled shape of the magnetic core assembly: adhesive fixing, binding fixing, heat shrink tubing fixing, and mechanical clamping fixing.

3. The customized magnetic core current sensor based on long magnetic sheet roll-and-stacking as described in claim 1, characterized in that, An insulating layer is provided on the outside of the magnetic core assembly to prevent short circuits or wear between the magnetic core assembly and the coil assembly. The insulating layer includes polyimide tape, PET insulating film or glass fiber insulating paper.

4. The customized magnetic core current sensor based on long magnetic sheet roll-and-stack as described in claim 1, characterized in that, The customized magnetic core current sensor also includes a hinged housing for encapsulating the magnetic core assembly and coil assembly.

5. A method for fabricating a customized magnetic core current sensor based on long magnetic sheet roll-and-stacking, used to realize the customized magnetic core current sensor based on long magnetic sheet roll-and-stacking as described in claims 1-4, characterized in that, include: Step 1: Obtain the circumference or diameter of the conductor being measured; Step 2: Determine the inner diameter of the magnetic core based on its circumference or diameter; Step 3: Calculate the cutting length of the long magnetic sheet based on the inner diameter of the magnetic core, the thickness of the magnetic sheet, and the number of layers rolled; Step 4: Cut the long magnetic sheet to the required length to obtain the magnetic sheet to be rolled. Step 5: Roll the magnetic sheet to be rolled into a ring-shaped stacked structure that matches the inner diameter of the magnetic core to obtain the magnetic core assembly; Step 6: Secure the magnetic core assembly to prevent springback and interlayer misalignment; Step 7: Wind the coil assembly around the outer periphery of the magnetic core assembly, add an insulation layer between the magnetic core assembly and the coil assembly, and lead out the cable of the coil assembly; Step 8: Package the magnetic core assembly and coil assembly to obtain the finished magnetic core current sensor.

6. The method for fabricating a customized magnetic core current sensor based on long magnetic sheet roll-up as described in claim 5, characterized in that, In step 2, after determining the inner diameter of the magnetic core, a clearance is reserved for installation.

7. The method for fabricating a customized magnetic core current sensor based on long magnetic sheet roll-up as described in claim 5, characterized in that, In step 6, the magnetic core assembly is fixed by means of adhesive bonding, binding, heat shrinking, or clamping.

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