Current monitoring in wire within electrical connector

Abstract

A current detection device for a wire comprises: a sleeve of a flexible material, wherein the sleeve is tubular and arranged to fit over a portion of the wire; an inductor comprising a first coil of a first wire carried by the sleeve formed of an electrically conductive material, and a second coil of a second wire disposed on the first wire, the second coil being helical in shape and having a first end extending to the first end of the second wire, and the second coil having a second end extending to the second end of the second wire, the second end part extends to the second end part of the second lead; and an integrator circuit coupled to the first end portion of the second wire and coupled to the second end portion of the second wire, and providing an output voltage that varies according to a magnitude of a current in the coil.

Description

Technical Field

[0001] This disclosure generally relates to electrical connectors and to means for measuring current within the wires of an electrical connector. In particular, this disclosure relates to a current sensing device for wires and to an electrical connector including said device. Additionally, this disclosure relates to a method of manufacturing said current sensing device. Background Technology

[0002] Electrical connectors are devices that allow current to flow between two or more circuits. They provide a robust and reliable connection for the transmission of power or signals. Depending on the specific application and requirements, electrical connectors are made in various types, shapes, and sizes. In electrical connectors, wires play a crucial role in establishing the electrical connection between the connector and the device to which it is connected. Wires are used to carry electrical signals or power between two mating connectors.

[0003] In some situations, measuring and / or monitoring the current flowing within the wires of an electrical connector is useful. For example, measuring current can help identify any faults or anomalies within a circuit. If the measured current deviates significantly from the expected or normal range, this may indicate a short circuit, overload, or other problems that need to be overcome. Measuring current also allows for the evaluation of circuit performance. This helps determine whether the current flowing through the wires is within the expected range and whether the circuit is functioning as intended. Furthermore, by comparing the measured current at different points in the circuit with expected values, this can help pinpoint the location of a fault or identify components that are not functioning correctly. In certain applications, such as electrical installations or industrial setups, measuring current may be necessary to ensure compliance with safety regulations and standards.

[0004] Several techniques can be used to monitor the current flowing in the wires of an electrical connector. For example, a current data logger can be connected in series with the wires within the connector to continuously measure and record current values ​​over specific time periods. These loggers store the data internally, which can later be downloaded and analyzed to understand current curves and trends. Some electrical connectors may have a built-in current monitoring module, which typically includes current sensing circuitry and an interface for data acquisition or communication. These allow for real-time monitoring and reporting of current values ​​within the connector. Power monitoring systems can also be used to monitor various electrical parameters, including current, voltage, power, and energy consumption. These systems typically include a current sensor or transducer that can be mounted in the wires of the connector to provide continuous monitoring of the current. However, these known solutions can be very expensive or complex to manufacture and are not always accurate, especially for monitoring wires within the connector that are bent or manipulated during connection. Summary of the Invention

[0005] According to a first aspect, a current sensing device for a conductor is provided. The current sensing device includes: a sleeve of flexible material, wherein the sleeve is tubular and arranged to be mounted above a portion of a conductor; a sensor including a first coil of a first conductor formed of a conductive material carried by the sleeve, and a second coil of a second conductor disposed on the first conductor, the second coil being helical in shape and having a first end extending to the first end of the second conductor, and the second coil having a second end extending to the second end of the second conductor; and an integrator circuit coupled to both the first and second ends of the second conductor, and providing an output voltage that varies according to the magnitude of the current in the coil.

[0006] According to a second aspect, an electrical connector is provided having a housing and a plurality of wires, wherein a portion of each wire is received within the housing, and wherein a current sensing device according to the first aspect is located on said portion of at least one of the wires.

[0007] According to a third aspect, a method for manufacturing a current sensing device for a conductor is provided. The method includes: providing a first conductor of conductive material; printing a second conductor of conductive material as a coil onto the first conductor, forming the first conductor as a coil before or after the printing step, wherein the second conductor has a diameter of 0.001 mm. 2 and 0.9 mm 2 The diameter between, and the second coil has a helical shape with a pitch between 0.4 degrees and 45 degrees.

[0008] Other aspects and features are defined in the appended claims.

[0009] Examples of this disclosure enable the provision of current sensing devices for conductors that are easy to manufacture and improve the accuracy of current sensing signals. Attached Figure Description

[0010] The following detailed description of preferred embodiments and best forms will be given with reference to the accompanying drawings, in which: Figure 1 The illustration shows a perspective cross-sectional view of an electrical connector in a connected state. Figure 2 The diagram shows the disconnected state. Figure 1 connector; Figure 3 This is a schematic view of an electrical connector, showing multiple wires of a cable connected to the connector; Figure 4 This is a view of the sleeve including the current sensing sensor; Figure 5It is a cross-sectional view including the wires of the sensor; Figure 6 This is a diagram of an integrator circuit, with a sensor connected to it; and Figure 7 This is an enlarged partial view of a portion of the sensor, showing the wires of the first coil, with a second coil of different wires wound around the wires of the first coil. Detailed Implementation

[0011] Please refer to the attached diagram for more details. Figures 1 to 3 The diagram illustrates an electrical connector 10 having a first portion 12 and a second portion 14, which are releasably coupled together to define an electrical connection between the portions. The first portion 12 and the second portion 14 of the electrical connector 10 may each include a housing therein receiving a plurality of connectors 16, each connector 16 having mating engagement features, which may include male and female structures, such as plugs / insertions and receptacles for receiving plugs / insertions. Each of the plurality of connectors includes electrical contacts, which, as desired, are arranged to allow power or data, or both, to pass through when the first and second portions are coupled together, and, if desired, wires 18 from each connector may extend in a common cable 20. Figure 1 An example of such an electrical connector is the Han-Modular® connector sold by Harting Technology Group, which may include a number of wires leading to a similar number of electrical contacts of one or more internal connectors. In other arrangements, the electrical connector may be a single connector and not a modular group of connectors, wherein the connector includes a first portion 12 and a second portion 14 having associated electrical contacts that are electrically coupled together when the two portions 12, 14 are slidably connected together.

[0012] like Figure 3 As shown, connector portions 12, 14 can be coupled to individual components (such as cable 20 and circuit board 22 or other components) to electrically connect these components via connector 10 as desired. Connector 10 provides multiple through-hole connections and can have any desired number of electrical contacts. Figure 3 The simplified diagram shows five pins or electrical contacts 24, each associated with a single wire 18. The pins or contacts 24 of each part 12, 14 of the connector 10 engage with each other to define a through-type electrical connection. Of course, these pins or electrical contacts are merely representative, and any number of contacts 24 and wires 18 can be used in any desired arrangement.

[0013] As mentioned above and Figure 1As best shown, cable 20 includes a plurality of individual conductors 18 within an outer cable sheath 26. Each conductor 18 leads to a separate contact 24 of connector portion 14, and as... Figure 5 As shown, each of the conductors 18 may comprise a conductive core 28 (typically copper) within an insulation layer 30 of a non-conductive material (typically a polymer). A cable sheath 26 may be coupled to a connector portion 14, and individual conductors 18 may extend beyond the sheath and into the interior of the housing 32 of the connector portion 12, as shown. Figure 1 As generally shown in the diagram. The wires 18 can be individually routed to and connected to the corresponding contacts 24 of the connector portion 14.

[0014] To enable the detection of alternating current in the conductor 18 of cable 20, a current sensing sensor 34 is arranged around a portion of the conductor 18. Figure 1 In the diagram, wire 18 is shown with a current sensing sensor 34 on a portion of wire 18. (See diagram for reference.) Figure 4 As shown, the sensor 34 is formed of a conductive material (such as copper) and includes a first coil 36 of conductive wires arranged in a spiral around the wire 18 and extending along the axial length of the wire 18, wherein the axis is the central axis 38 of the spiral. The wires of the first coil 36 include an insulating layer 37 surrounding the conductive inner wire material. Additionally, as... Figure 4 and Figure 7 As shown, the sensor 34 includes a second coil 39 with conductive wires arranged in a spiral around the wires of the first coil 36, wherein the inner diameter of the spiral of the second coil 39 is approximately equal to the outer diameter of the wires of the first coil 36 (including the insulating layer 37). A first end 40 and a second end 42 of the second coil 39 are connected to an integrator circuit 44, wherein a portion of the wires of the second coil 39 (e.g., a return lead 45) passes radially through the first coil 36, as is the case in a Rogowski coil.

[0015] In at least some embodiments, an inductor 34, including a first coil 36 and a second coil 39, is disposed on a tubular sleeve 46, which is then fitted onto the wire 18 above the insulation layer 30 of the wire 18, such as... Figure 5As shown in the diagram, the sleeve 46 may be formed of a flexible material to allow the sleeve 46 and the sensor 34 to bend as the wire 18 is bent. Representative, but not limiting, materials for the sleeve 46 include various flexible plastics or rubber- or rubber-like materials, such as PVC, TPU, any elastomer, and silicone. The sleeve 46 and the sensor 34 on the sleeve may have any desired axial length, with some embodiments including axial lengths between 1 cm and 10 cm, where the referred axis is the axis of the wire 18. In at least some embodiments, the inner diameter of the sleeve 46 is sized to allow the sleeve to slide onto the outer surface of the insulation layer 30 of the wire 18, such as between 1 and 2 times the outer diameter of the wire, and the sleeve 46 has a thickness between 0.3 mm and 1 cm. In this embodiment, the inner diameter of the helix of the first coil 36 is approximately equal to the outer diameter of the sleeve 46.

[0016] In at least some embodiments, the sensor 34 may be applied to the outer surface 48 of the sleeve 46 in a helical pattern. A first end 50 of the first coil 36 may be closer to a first end 52 of the sleeve 46 than to a second end 54 of the sleeve, and a second end 56 of the first coil 36 may be closer to a second end 54 of the sleeve than to a first end 52. In at least some embodiments, a return lead 45 (including a portion of the conductor of the second coil 39 extending between the second end 56 of the first coil 36 and the second end 42 of the conductor of the second coil 39) extends radially inward from the second end 56 of the first coil 36 into the interior of the sleeve 46 and extends back out of the first end 52 of the sleeve, such that the second end 42 of the conductor of the second coil 39 can be connected to the integrator circuit 44 and defines the complete circuit. In at least some embodiments, the second coil 39 of the sensor 34 is applied to the conductor of the first coil 36 by 3D printing of copper wire material. The 3D printing process allows the desired cross-sectional area of ​​the wires and the helical pitch or pitch range to be maintained along the axial length of the second coil 39, which improves the accuracy of the current detection signal provided by the sensor 34. Furthermore, the sleeve material ensures that the sensor 34 has a constant diameter. The sensor 34 can be molded from the material of the sleeve 6 (e.g., by impregnation or otherwise setting the sleeve material onto the sensor), the sensor can be adhered to the sleeve of polymer or fabric material, or the sensor can be otherwise disposed on or within the material of the sleeve.

[0017] In at least some embodiments, the material of the second coil 39 is applied as a cylindrical conductor (i.e., circular in cross-section), but other shapes, including elliptical, rounded rectangular, or rectangular, may be used. In at least some embodiments, the conductor of the first coil 36 may have a diameter of 0.01 mm. 2 and 0.5 mm 2The cross-sectional area between them, and the wire of the second coil 39 may have 0.001 mm. 2 and 0.9 mm 2 The cross-sectional area between them. In addition, in at least some embodiments, the pitch of the helix of the first coil 36 may be between 1 degree and 60 degrees, wherein the maximum deviation of the pitch along the length of the first coil 36 is about 10 degrees, and the pitch of the helix of the second coil 39 may be between 0.4 degrees and 45 degrees, wherein the maximum deviation of the pitch along the length of the second coil 39 is about 10 degrees.

[0018] In at least some implementations, such as in Figure 5 As shown, a protective layer or shielding layer 60 may be disposed above the sleeve 46 and the sensor 34 to reduce the influence of magnetic fields from other wires interfering with the current detection of the selected / intended wire 18. The shielding layer 60 may be formed of any suitable material and may be 3D printed over the sleeve 46 on which the sensor 34 is disposed, or the sleeve 46 on which the sensor 34 is disposed may be overmolded by the shielding layer 60 (e.g., by impregnation or otherwise setting the sleeve material onto the sensor), or the shielding layer may be slidably disposed over the sleeve, as desired. The shielding layer 60 may be formed of any suitable material used to dampen, reduce, or suppress external magnetic fields from reaching the sensor 34, and the shielding layer 60 may also help contain or concentrate the magnetic field generated by the selected / intended wire 18 to improve current detection in the selected / intended wire. The shielding layer 60 may be formed of aluminum or other metals.

[0019] The integrator circuit 44 can be arranged as is known with respect to Rogowski coils, and includes both passive and active integrators. A simple active integrator circuit 44 is shown in... Figure 6 The amplifier 62 includes an amplifier 62 and an RC element. The amplifier 62 has a negative terminal 64 connected to an input resistor 66 and a positive terminal 68 connected to ground. The RC element includes a resistor 70 and a capacitor 72 connected in parallel in the feedback path of the amplifier 62.

[0020] In operation, when an alternating current is applied to the conductor 18, a magnetic field is generated. This magnetic field induces a current in the inductor 34, which is then supplied as an input to the integrator circuit 44. The integrator circuit 44 provides a voltage at its output terminal 74, which varies according to the magnitude of the current induced in the inductor 34. In this way, the magnitude of the alternating current in the conductor 18 can be determined.

[0021] Desiredly, the sensor 34 can be positioned very close to the outer surface of the insulation layer 30 of the conductor 18, such that a single conductor 18 among multiple conductors can have current monitoring capability in a relatively small space (such as within the housing or body of an electrical connector). Known Rogowski coils are large and involve a large air gap between the Rogowski coil and the conductor whose current is being determined / detected. The magnetic field is weaker at the Rogowski coil, and to address this, additional coils are provided, making the device even larger. In at least some embodiments, the sensor 34 described herein is positioned very close to the conductor 18 being monitored and can be on a sleeve 46 directly on the outer surface 30 of the conductor 18. This arrangement increases the strength of the magnetic field in the region where the sensor 34 is positioned close to the conductor and improves the sensitivity of the device.

[0022] Furthermore, in the case of 3D-printed coil 39, the dimensions and pitch of the coil wires and coil shape of the second coil 39 can be reliably and repeatably achieved within tight tolerances, improving the accuracy of current monitoring of the current sensing sensor 34 in a production batch. In a non-limiting example, the printed wires of the second coil 39 can be as small as 50 micrometers in diameter, and the pitch of the helix can be as small as 50 micrometers, enabling a high number of windings per unit / axial length of the second coil. 3D printing or other material deposition processes offer better accuracy compared to mechanically winding pre-formed wires (although such processes can be used). Additionally, the flexible nature of the sleeve allows the sensor to be used on wires 18 that can be bent or otherwise manipulated during connection in an electrical connector.

[0023] All terms used in the claims are intended to be given the broadest reasonable interpretation and their general meaning as understood by one of ordinary skill in the art, unless expressly indicated otherwise herein. In particular, the use of singular articles such as “a,” “the,” “the,” etc., should be interpreted as referring to one or more of the indicated elements, unless the claims expressly limit to the contrary.

Claims

1. A current detection device for a conductor, comprising: A flexible material sleeve, wherein the sleeve is tubular and arranged to be fitted over a portion of a wire; The sensor includes a first coil of a first wire formed of a conductive material carried by the sleeve, and a second coil of a second wire disposed on the first wire, the second coil being helical in shape and having a first end extending to a first end of the second wire, and the second coil having a second end extending to a second end of the second wire; as well as An integrator circuit is connected to the first end of the second conductor and to the second end of the second conductor, and provides an output voltage that varies according to the magnitude of the current in the coil.

2. The apparatus of claim 1, wherein the second coil is formed by 3D printing of the second conductor.

3. The apparatus of claim 2, wherein the second conductor is formed of copper.

4. The apparatus of claim 1, wherein the first conductor has a diameter of 0.01 mm. 2 and 0.5 mm 2 The cross-sectional surface area between them, and the second conductor has a cross-sectional surface area of ​​0.001 mm. 2 and 0.9 mm 2 The cross-sectional surface area between them.

5. The apparatus of claim 4, wherein the first coil has a pitch between 1 degree and 60 degrees, and the second coil has a pitch between 0.4 degrees and 45 degrees.

6. The apparatus of claim 1, wherein the second coil has a pitch between 0.4 degrees and 45 degrees, and the second conductor has a pitch of 0.001 mm. 2 and 0.9 mm 2 The cross-sectional surface area between them.

7. The apparatus of claim 1, wherein the first coil has a first end adjacent to a first end of the sleeve, and the first coil has a second end adjacent to a second end of the sleeve, and a portion of the second conductor between the second end of the first coil and the second end of the second conductor extends inside the sleeve and is accessible at the first end of the sleeve.

8. An electrical connector having a housing and a plurality of wires, wherein a portion of each wire is received within the housing, wherein the current sensing device of claim 1 is on said portion of at least one of the wires.

9. A method for manufacturing a current detection device for a conductor, comprising: A first conductive wire provided with conductive material; A second conductive wire of conductive material is printed as a coil onto the first conductive wire, and the first conductive wire is formed into a coil before or after the printing step, wherein the second conductive wire has a diameter of 0.001 mm. 2 and 0.9 mm 2 The diameter between the two, and the second coil has a helical shape with a pitch between 0.4 degrees and 45 degrees.

10. The method of claim 9, further comprising providing a sleeve around which the first coil is received.

11. The method of claim 10, comprising the following steps: The first end of the second conductor is spaced apart from the first end of the sleeve; the first end of the first coil is positioned adjacent to the first end of the sleeve; the second end of the first coil is positioned adjacent to the second end of the sleeve; and the second end of the second conductor is positioned such that a portion of the second conductor extending from the second end of the first coil to the second end of the second conductor is received inside the sleeve.

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