Sensors, protective circuit breakers, charging cables, and charging stations

Abstract

To provide a sensor, a protection circuit breaker, a charging cable, and a charging station capable of achieving improvement or alternatives to the prior art.SOLUTION: The invention relates to a sensor (100) having, as a result of a passage in a shield (50) having a clear width of 25.2 to 32 mm, higher sensitivity for an electrical differential current, more particularly for universal-current sensitive determination of an electric differential current, over the prior art on the one hand and on the other hand a lower probability of a faulty detection of a differential current purportedly exceeding a limit current when a monitored circuit is switched on. The invention further relates to a circuit breaker, a charging cable and a charging station, each comprising a sensor of this kind.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to sensors, protective circuit breakers, charging cables, and charging stations.

Background Art

[0002] Sensors for determining residual currents are known in various designs and various applications, especially since residual currents can pose a danger to people and cause fires.

[0003] Residual currents occur when there are defects in the power supply network, especially in the circuits within the power supply network, so that fault currents in the power supply network can flow towards the ground. Depending on the type and structure of the power supply network, the residual current can have an AC component and / or a DC component.

[0004] Due to the continuous expansion of the use of renewable energy, electromobility, variable-speed electric machines and / or the like, the number of electrical systems that combine AC and DC supply networks with each other is increasing. As a result, the importance of the DC component of the residual current is increasing more and more.

[0005] Typically, especially in household electrical equipment, only one type A fault current protection circuit breaker is incorporated, which can monitor the household electrical supply network for residual currents including AC components, but cannot detect or interrupt DC faults. However, the use of DC elements is also increasing in household electrical equipment, such as when charging electric vehicles or when operating solar systems.

[0006] Therefore, all-current-sensitive monitoring of residual currents is required, including a residual current sensor that shuts down the relevant infrastructure when the detected measured value exceeds a limit value, especially during the operation of charging infrastructure or solar inverters or the like.

[0007] For the operation of charging infrastructure or solar inverters, or similar devices, Type B fault current protection circuit breakers (Fl-Schutzschalter) are known, which can also detect and monitor the DC component of residual current. However, Type B fault current protection circuit breakers are relatively expensive.

[0008] Dual-current-sensitive residual current sensors simultaneously monitor all currents flowing through phase and neutral conductors to detect possible DC and AC faults. Depending on the application, the sensor can autonomously control system shutdown in the event of an error or report exceeding a switching threshold to a higher-level control unit. Due to the extremely small acceptable fault current, excellent measurement accuracy is required. Furthermore, for personal safety, system-wide detection, especially rapid detection and subsequent shutdown, is essential.

[0009] Known residual current sensors are based on configurations in which, for example, a magnetic core is placed around a conductor being monitored, with an air gap. When current flows, a magnetic field is induced by the magnetic core. In known configurations, a Hall element is placed in the air gap, which generates an output voltage depending on the magnetic field strength. To improve measurement accuracy, a compensation winding can be provided attached to the magnetic core. This is achieved by electrically compensating for the magnetic field generated by the monitored current and adjusting the zero position of the Hall sensor. In this case, the original output signal of such a sensor represents the current required by the compensation winding.

[0010] Furthermore, it is known that so-called flux-gate sensors are used to measure the magnetic field generated by the flow of electric current. In this method, a primary coil is wound around a magnetic core and driven by alternating current. The output signal, which depends on the residual current, is extracted by a secondary pickup coil. [Overview of the project] [Problems that the invention aims to solve]

[0011] This invention is based on the objective of providing an improvement or alternative to the prior art. [Means for solving the problem]

[0012] According to a first aspect of the present invention, a sensor for determining residual current, particularly for determining residual current in a dual-current-sensitive manner, - The sensor comprises a magnetic field-sensitive element, a first main winding, a test winding, and a shielding body. - The magnetic field-sensitive element has a through-aperture, and the through-aperture of the magnetic field-sensitive element is formed as an oval with two axes of symmetry in its cross-section. -A first main winding and a test winding, each having multiple windings, surround the magnetic field-sensitive element. - The shielding body has a housing space configured to accommodate a magnetic field-sensitive element, a first main winding, and a test winding. - The containment space of the shielding body is defined radially by the outer wall and inner wall of the shielding body. - The inner wall of the shield defines a through-opening in the shield, and the through-opening in the shield is formed as an oval with two axes of symmetry. - The shielding body has a gap that extends circumferentially in the region of the inner wall of the shielding body, - The sensors are configured to be positioned around at least two electrical conductors. - The through-aperture of the magnetosensible element has at least one inner width along the axis of symmetry, - The sensor solves the problem, wherein the through-aperture of the magnetically sensitive element has at least one inner width along the axis of symmetry, and at least one inner width is in the range of 25.2 to 32 mm, preferably 25.5 to 29 mm, and particularly preferably 25.8 to 27 mm.

[0013] In this regard, let me explain the following terms: First, it should be made clear that, where it is not clear from the context, or where it is clear or technically necessary to a person skilled in the art that it may refer to "exactly one," "exactly two," etc., within the scope of this patent application, indefinite articles and numbers such as "one," "two," etc. should generally be understood as "at least," i.e., "at least one," "at least two," etc.

[0014] Within the scope of this patent application, the expression “especially” should always be understood to mean that an optional and preferred feature is introduced by this expression. This expression should not be understood as “strictly” or “that is to say.”

[0015] A "sensor," or more specifically, a "detector," is a technical assembly capable of detecting certain physical or chemical properties and / or material characteristics in its surroundings, either qualitatively or quantitatively, as "measured quantities." These quantities are detected using physical or chemical effects and converted into analog or digital electrical signals. Such signals are also called "sensor signals."

[0016] In particular, the sensor signal is proportional to the power consumption, especially the power consumption of the test winding and / or the first main winding and / or the second main winding. Specifically, the sensor signal, especially the sensor signal of the test winding and / or the first main winding and / or the second main winding, can be converted to power consumption using mathematical rules.

[0017] "Power consumption" is understood as the current intensity flowing through a circuit, particularly the test winding and / or the first main winding and / or the second main winding, at a defined voltage. It should be clearly noted that the term power consumption does not require information regarding the sign of the current. In particular, power consumption can correspond to a positive or negative current.

[0018] The sensor signal is preferably understood to mean the power consumption of the first main winding. In particular, the power consumption of the first main winding can be converted into one residual current of the circuit specified and monitored by the sensor using mathematical rules. In particular, this mathematical rule can be determined by the calibration curve of the sensor.

[0019] The "residual current" is understood to be the vector sum of the currents of all electrical conductors in which the sensor is arranged around.

[0020] The residual current can have an AC component and / or a DC component.

[0021] Determining the "residual current" in a two-current sensing manner is understood to mean that the sensor is set so that it can determine both the AC component and the DC component.

[0022] The "magnetic field sensitive element" is understood to be an element that reacts to a magnetic field by a change in at least one state quantity of the element.

[0023] In particular, the magnetic field sensitive element is understood to be a substance having magnetic properties.

[0024] The magnetic field sensitive element is particularly preferably understood to be a soft magnetic material.

[0025] The "soft magnetic material" is understood to be a material that can be easily magnetized in a magnetic field. In particular, the soft magnetic material has a coercive force of 1,000 A / m or less.

[0026] The "coercive force" is understood to be the magnetic field strength required to completely demagnetize the magnetic field sensitive element before it is charged to the saturation magnetic flux density.

[0027] In particular, the soft magnetic material is understood to be a material made from amorphous metal and having a nanocrystalline structure.

[0028] In particular, the soft magnetic material has an alloy containing iron, nickel and cobalt.

[0029] A "winding" is understood to be a winding of a solid aggregate of conductive material, particularly in the form of a wire, extending around a magnetic field-sensitive element.

[0030] The "main winding" is understood to be a winding that is configured to be actively supplied with current by a current source. Alternatively, the main winding can be connected to a voltage source. The main winding can also be called the "first main winding."

[0031] In particular, the main windings, especially the first main winding, are configured to provide sensor signals indirectly, particularly through the power consumption of the main windings, and especially through the power consumption of the first and / or second main windings.

[0032] In particular, the residual current of a specified circuit monitored by a sensor can be determined from the power consumption of the main windings, especially the first and / or second main windings, using mathematical rules, particularly mathematical rules that can be derived from the calibration of the sensor.

[0033] A "test winding" is understood to be a winding configured to flow as a completely passive element, resulting in current flow as a result of the inductive effect from a magnetic field-sensitive element. The test winding can be configured to provide a test winding signal that can be used within the calibration range of the sensor. In particular, the test winding has a significantly different number of turns compared to the main winding.

[0034] In particular, sensor calibration is always performed before the actual measurement operation begins, whenever a measurement operation is initiated.

[0035] A "shielding element" is understood to be an element designed to keep electric and / or magnetic fields away from a magnetic field-sensitive element, and / or to protect the area around the sensor from electric and / or magnetic fields generated by the sensor.

[0036] In particular, the shielding body is made of an alloy having 20% ​​by weight or more nickel, preferably 30% by weight or more nickel, and especially preferably 50% by weight or more nickel. It is even more preferable that the shielding body is made of an alloy having 60% by weight or more nickel, more preferably 70% by weight or more nickel, and especially preferably 80% by weight or more nickel.

[0037] In particular, the shielding body is made of an alloy having 0.5% by weight or more molybdenum, preferably 1% by weight or more molybdenum, and especially preferably 3% by weight or more molybdenum. It is even more preferable that the shielding body is made of an alloy having 4% by weight or more molybdenum, more preferably 5% by weight or more molybdenum, and especially preferably 5.5% by weight or more molybdenum.

[0038] In particular, the shielding body is made of an alloy having 10% or more by weight of iron, preferably 20% or more by weight of iron, and especially preferably 30% or more by weight of iron. It is even more preferable that the shielding body is made of an alloy having 40% or more by weight of iron, more preferably 50% or more by weight of iron, and especially preferably 55% or more by weight of iron.

[0039] It should be clearly stated that the above values ​​regarding the alloy composition of the shielding material should not be understood as definite limits, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the embodiments of the invention described herein. In short, these values ​​should provide an index of the magnitude of the alloy composition of the shielding material proposed herein.

[0040] In particular, the shielding body is formed in a multi-part configuration, especially a two-part configuration.

[0041] Particularly preferable, the two-part shielding body is formed such that the two shielding body portions overlap each other, or at least partially overlap each other, on the outer wall of the shielding body.

[0042] Furthermore, more preferably, the two-part shielding body is formed such that the two shielding body portions do not come into contact with each other in the inner wall of the shielding body, and the two shielding body portions of the two-part shielding body preferably form a gap in the inner wall of the shielding body.

[0043] A "through-aperture" is understood to be a free cross-section (freier Querschnitt) formed in the internal region of a magnetic field-sensitive element.

[0044] Particularly preferably, the outer contour of the magnetic field-sensitive element is designed as an oval, and the inner contour of the magnetic field-sensitive element is also formed as an oval having two axes of symmetry.

[0045] The inner contour of the magnetic field-sensitive element forms a through-aperture of the magnetic field-sensitive element.

[0046] In particular, the material thickness of the magnetic field-sensitive element is approximately constant or constant. In special cases where the magnetic field-sensitive element is formed with a circular cross-section and the material thickness of the magnetic field-sensitive element is constant, the magnetic field-sensitive element has a geometric shape with a circular cross-section.

[0047] An "oval" is a flat, rounded, convex shape. Ovals include circles and ellipses as special cases, and unlike these, any oval does not need to have an "axis of symmetry". In particular, an oval is a closed convex curve on a plane that is twice continuously differentiable.

[0048] An oval has an axis of symmetry if its curve is mirrored on both sides of an imaginary line. An oval has "two axes of symmetry" if its curve is mirrored on both sides of two non-contiguous imaginary lines. In particular, a circle and an ellipse are both ovals with two axes of symmetry.

[0049] "Winding" is understood as the circumference (Umlauf) of the winding around a magnetic field-sensitive element.

[0050] The "encompassing space" is a space formed by the shielding inside the shielding and is configured to accommodate other elements, particularly magnetic field-sensitive elements, the first main winding, and the test winding, as well as the second main winding, the insulator, and the spacer ring.

[0051] "Radial direction" is understood to mean the direction extending linearly radially from the central axis of the sensor, which extends in the direction normal to the cross-sectional area of ​​the through-opening as small as possible.

[0052] The term "shielding outer wall" is understood to refer to the radially outer surface formed by a shielding body, particularly a two-part shielding body that is fitted together with one another.

[0053] The term "internal wall of the shielding body" is understood to refer to the radially inner surface, particularly the projection surface, which may have a partial surface, of the shielding body located on the inside and the gap extending in the circumferential direction, formed by the shielding body.

[0054] "Circumferentially extending gaps" are understood to be gaps that extend circumferentially within the inner wall of a shielding body, between partial surfaces of the inner wall of the shielding body formed by the shielding body. When viewed radially and from the central axis, circumferentially extending gaps cause the shielding body to open in the direction of the space containing the shielding body.

[0055] An "electrical conductor" is understood to be any medium that has mobile charge carriers and is therefore capable of transporting electric charge. In particular, an electrical conductor is understood to be a copper cable and / or aluminum cable as a conductor through which electrons can move.

[0056] The "internal width" along the axis of symmetry of the through-opening is understood to be the extension of the through-opening in the direction and height of the observed axis of symmetry.

[0057] If the ellipse forming the through-aperture of the magnetic field-sensitive element has two axes of symmetry that extend in different directions along the axis of symmetry, a first inner width is generated along the first axis, and a second inner width is generated along the second axis of symmetry.

[0058] In this specification, when simply referred to as "internal width," it means the internal width along the axis of symmetry having the larger extension.

[0059] "Limit current" is understood to be the residual current that, when detected by the sensor, reaches or exceeds the limit current of the protective circuit breaker, and which the sensor can detect with sufficient accuracy and speed, thereby causing the protective circuit breaker to interrupt the voltage in the circuit monitored by the sensor.

[0060] The smaller the limit current of the protective circuit breaker, and therefore the smaller the measurement suitability of the slight residual current in the sensor, and the faster and more reliably the sensor can detect this, the less danger there is that could arise from the residual current.

[0061] Prior art is known for sensors having a smaller internal width of the through-aperture of the magnetic field-sensitive element than that proposed here.

[0062] In particular, conventional efforts have been made to reduce the internal width of the through-aperture of magnetic field-sensitive elements.

[0063] The motivation for this effort is that the need to detect residual currents more quickly and with smaller values ​​necessitates placing the magnetic field-sensitive element as close as possible to the energized electrical conductors of the circuit being monitored.

[0064] The magnetic field strength generated by an electrically energized conductor decreases inversely with increasing distance from the conductor. Therefore, the further a magnetic field-sensitive element is from the electrically energized conductor of the monitored circuit, the lower the magnetic flux density in the magnetic field-sensitive element, which is caused by the magnetic field strength around the electrically energized conductor.

[0065] To further reinforce this, the magnetic field strengths of at least two energized electrical conductors in the monitored circuit, both of which need to pass through the through-aperture of a magnetic field-sensitive element to monitor residual current and whose current flows in opposite directions, are superimposed and, ideally speaking, cancel each other out, provided that no residual current is generated in the monitored current circuit.

[0066] As a result, the magnetic field strength acting on the magnetic field-sensitive element becomes particularly low when the residual current of the monitored circuit is small, which in turn generates a particularly small magnetic flux density in the magnetic field-sensitive element.

[0067] The lower the magnetic flux density in the magnetic field-sensitive element, the lower the current that the magnetic flux density in the magnetic field-sensitive element generates in the test winding and / or the first main winding and / or the second main winding.

[0068] In other words, the larger the inner width of the through-aperture of the magnetic field-sensitive element, the greater the distance between the magnetic field-sensitive element and the electrical conductor of the monitored circuit, which means that small residual currents cannot be detected at all, or can only be detected with special difficulty.

[0069] For this reason, the requirement to detect relatively small residual currents leads to technical efforts to minimize the inner width of the through-aperture of the magnetic field-sensitive element.

[0070] Minimizing the magnetic field-sensitive element as much as possible also leads to lighter sensors, reduced material requirements, and therefore lower costs and space requirements.

[0071] Therefore, many factors contribute to reducing the inner width of the through-aperture of the magnetic field-sensitive element.

[0072] Conventional knowledge has shown that protective circuit breakers with very small residual currents tend to malfunction when the monitored circuit is turned on.

[0073] The reason for this is that when the circuit is turned on, conventional sensors generate a sensor signal that can be interpreted as residual current, even though there should be no residual current in the monitored circuit. The requirement to reduce residual current means an increase in the number of malfunctions of protective circuit breakers.

[0074] However, contrary to conventional knowledge, laboratory experiments unexpectedly discovered that there is an optimal range for the inner width of the through-aperture of the magnetic field-sensitive element that allows for the detection of the smallest possible residual current within a sufficient time, while simultaneously significantly reducing the possibility of malfunction of the protective circuit breaker connected to the sensor. This discovered range requires a larger inner width for the through-aperture of the magnetic field-sensitive element than previously known with conventional technology.

[0075] In other words, a range of through-aperture widths was discovered that robustly determines the smallest possible residual current, thereby ensuring that when the circuit monitored by the sensor is turned on, no sensor signals exceeding the required limit current, which can be interpreted as residual current, are generated, or only very rarely.

[0076] To achieve the minimum limiting current in a monitored circuit that can be robustly determined by the sensor, it is proposed that the inner width of the through-aperture of the magnetic field-sensitive element be in the range of 25.2 to 32 mm.

[0077] Preferably, the inner width of the through-aperture of the magnetic field-sensitive element is proposed to be in the range of 25.5 mm to 29 mm.

[0078] Particularly preferably, the inner width of the through-aperture of the magnetic field-sensitive element is proposed to be in the range of 25.8 mm to 27 mm.

[0079] It should be clearly stated that the above values ​​for the inner width of the through-aperture of the magnetic field-sensitive element should not be understood as definite limits, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the embodiments of the invention described herein. In short, these values ​​should provide an index of the magnitude of the inner width of the through-aperture of the magnetic field-sensitive element proposed herein.

[0080] Needless to say, the limits of the range in which the inner width is specified can be combined arbitrarily.

[0081] When the voltage supply is turned on in the monitored circuit, a physical interaction is established between the magnetic field spreading around the electrical conductor and the magnetic flux density that is in relation to it.

[0082] As a result, when switched on, the magnetic field-sensitive element generates short-duration, time-varying pulses of magnetic flux that are primarily location-dependent.

[0083] This primarily leads to the oscillation behavior of magnetic flux in magnetic field-sensitive elements.

[0084] This short-duration oscillation behavior in the magnetic field-sensitive element causes a brief pass-through current flow in the test winding and / or the first main winding and / or the second main winding, which are in interaction with the magnetic field-sensitive element, via induction.

[0085] Laboratory experiments have shown that this could result in a short-lived sensor signal that could be interpreted as residual current, potentially exceeding a predetermined limit current during the specified operation of the sensor in the protective circuit breaker. This could lead to the protective circuit breaker shutting down when the voltage source of the monitored circuit is turned on.

[0086] Several different factors exert damping effects on this short-term vibration behavior. Some of these factors cannot be influenced by design measures.

[0087] Laboratory experiments have revealed that one of these factors is determined by the spacing between electrical conductors to be monitored by the sensor proposed here. The larger the aforementioned distance or spacing, the stronger the dynamic relationship between the electrical conductors and the sensor signal when the voltage source is turned on.

[0088] Regarding the spacing of electrical conductors in the cross-section of the through-aperture of a magnetic field-sensitive element, safety concerns arise, and increasingly larger spacing is required to avoid short circuits between electrical conductors. This amplifies this factor, increasing the tendency for undesirable sensor signals to be generated when the circuit is turned on.

[0089] Similarly, another factor confirmed in laboratory experiments is related to the ratio of the distance between a first electrical conductor and a different electrical conductor relative to a single point in a magnetic field-sensitive element. The further this ratio deviates from 1, the larger the short-term regional difference (regionale Unterschiede) in magnetic flux density in the magnetic field-sensitive element becomes. The larger these regional differences, the stronger the amplification of the sensor's dynamic starting behavior when the circuit is turned on.

[0090] By increasing the inner width of the through-aperture of the magnetically sensitive element, the ratio of the distance between the first electrical conductor and a different electrical conductor to a point in the magnetically sensitive element can be brought closer to a numerical value of 1, thereby advantageously achieving the damping effect of the sensor behavior due to the switch-on effect described above.

[0091] Increasing the inner width of the magnetic field-sensitive element leads to a decrease in sensitivity, especially to small residual currents. Therefore, an optimal range for the inner width of the through-aperture of the magnetic field-sensitive element is proposed here, taking into account two physical effects: on the one hand, it allows for the detection of minimal residual currents during normal sensor operation within a sufficient time; on the other hand, it prevents the generation of sensor signals that indicate false detection of non-existent residual currents when the power grid monitored by the sensor is turned on.

[0092] Specifically, it is proposed here to configure the sensor so that it can be placed around all conductors of a circuit that introduces current to the monitored circuit and derivates current to the monitored circuit during normal operation. In particular, it is proposed that the sensor proposed here not be placed around a protective conductor (Schutzleiter).

[0093] In particular, it is proposed that the sensor proposed herein be positioned around the outer conductor and the neutral conductor in the specified use in a single-phase power grid. Thus, the sensor will be positioned around the two electrical conductors in a single-phase power grid.

[0094] Furthermore, for the specified use in a three-phase power grid, it is proposed to position the sensors around the three outer conductors and the neutral conductor. Thus, in a three-phase power grid, the sensors will be positioned around a total of four electrical conductors.

[0095] In particular, it is proposed that the through-aperture of the magnetic field-sensitive element has a circular cross-section, that is, an oval with two semi-radii of equal length.

[0096] Furthermore, it is proposed that the through-aperture of the magnetic field-sensitive element has an elliptical cross-section, that is, an oval with two semiradii of different lengths.

[0097] It should be clearly stated that the characteristic of the through-aperture of the magnetic field-sensitive element being formed as an oval with two axes of symmetry in cross-section is not essential in the context of this invention.

[0098] Rather, other geometric shapes of the magnetic field-sensitive element can be considered here that allow for a good compromise with respect to the physical effects described above. In particular, these geometric shapes are also based on an oval cross-section.

[0099] It is proposed that the geometric shape of the shielding material be appropriately adapted to the geometric shape of the magnetic field-sensitive element.

[0100] Specifically, it is proposed here that the magnetic field-sensitive element also possess high magnetic permeability.

[0101] The "permeability" of a magnetic field-sensitive element is understood as the magnetization of the material in an external magnetic field. The higher the permeability of a magnetic field-sensitive element, the greater the ratio of the magnetic flux density in the element to the magnetic field strength acting on it.

[0102] A magnetic field-sensitive element with high permeability allows for a relatively high magnetic flux density even at low magnetic field strengths. Therefore, the high permeability of the magnetic field-sensitive element enhances the sensor's sensitivity, enabling detection even of small residual currents.

[0103] In particular, it is proposed that the magnetic field-sensitive element has a permeability of 35,000 H / m (Henry per meter) or more, preferably 45,000 H / m or more, and especially preferably 50,000 H / m or more. Even more preferably, the magnetic field-sensitive element has a permeability of 60,000 H / m or more, preferably 70,000 H / m or more, and especially preferably 80,000 H / m or more. Even more preferably, the magnetic field-sensitive element has a permeability of 90,000 H / m or more, preferably 100,000 H / m or more, and especially preferably 110,000 H / m or more. More preferably, the magnetic field-sensitive element has a permeability of 120,000 H / m or more, preferably 130,000 H / m or more, and particularly preferably 140,000 H / m or more. In particular, the permeability of the magnetic field-sensitive element is preferably 150,000 H / m or more.

[0104] The permeability values ​​above apply when the magnetic field oscillates at 50 Hz.

[0105] It should be clearly stated that the above values ​​for the permeability of the magnetic field-sensitive element should not be understood as definite limits, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the embodiments of the invention described herein. Simply put, these values ​​should provide an indicator of the magnitude of the permeability of the magnetic field-sensitive element proposed herein.

[0106] In particular, the magnetic field-sensitive element has a magnetic saturation flux density of 1 T or more, preferably 1.1 T or more, and especially preferably 1.2 T or more. In particular, the magnetic field-sensitive element has a magnetic saturation flux density of 1.3 T or more.

[0107] It should be clearly stated that the above values ​​for the magnetic saturation flux density of the magnetic field-sensitive element should not be understood as a clear limit, but rather should be able to exceed or fall below it on an engineering scale without departing from the embodiments of the invention described herein. Simply put, the values ​​should provide an indicator of the magnitude of the magnetic saturation flux density of the magnetic field-sensitive element proposed herein.

[0108] In particular, it is proposed that the magnetic field-sensitive element exhibits a high degree of linearity with respect to magnetic permeability, and especially higher linearity than that of ferrite material. In other words, it is proposed that ferrite material not be used in the magnetic field-sensitive element.

[0109] The higher the linearity of the magnetic permeability of a magnetic field-sensitive element, the higher the measurement accuracy that the sensor can achieve.

[0110] In particular, the magnetic field-sensitive element has a coercivity of 30 mA / cm or less, preferably 20 mA / cm or less, and especially preferably a magnetic electromagnetic field-sensitive element has a coercivity of 15 mA / cm or less. Even more preferably, the magnetic field-sensitive element has a coercivity of 10 mA / cm or less, preferably 5 mA / cm or less, and especially preferably a magnetic electric field-sensitive element has a coercivity of 2 mA / cm or less. Even more preferably, the magnetic field-sensitive element has a coercivity of 1 mA / cm or less, preferably 0.5 mA / cm or less, and especially preferably a magnetic electric field-sensitive element has a coercivity of 0.2 mA / cm or less. In particular, the magnetic field-sensitive element preferably has a coercivity of 0.1 mA / cm or less.

[0111] The above coercivity values ​​apply when the magnetic field oscillates at 50 Hz.

[0112] In particular, when the magnetic field strength changes, a low coercivity of the magnetosensible element allows for especially high measurement accuracy. The lower the coercivity of the magnetosensible element, the higher the measurement accuracy of the sensor.

[0113] It should be clearly stated that the above values ​​for the coercivity of the magnetic field-sensitive element should not be understood as definite limits, but rather should be able to exceed or fall below them on an engineering scale without departing from the embodiments of the invention described herein. Simply put, the values ​​should provide an indicator of the magnitude of the coercivity of the magnetic field-sensitive element proposed herein.

[0114] In particular, it is proposed to select or manufacture magnetic field-sensitive elements made of soft magnetic materials.

[0115] In particular, the magnetic field-sensitive element is made of an alloy containing 70% or more by weight of iron, preferably 71.5% or more by weight of iron, and especially preferably 73% or more by weight of iron. In particular, the magnetic field-sensitive element is made of an alloy containing 73.5% or more by weight of iron.

[0116] In particular, the magnetic field-sensitive element is made of an alloy containing copper in the range of 0.75 to 1.25 wt%, preferably in the range of 0.85 to 1.15 wt%, and especially preferably in the range of 0.95 to 1.05 wt%. In particular, the alloy of the magnetic field-sensitive element contains copper at a ratio of 1 wt%.

[0117] In particular, the magnetic field-sensitive element is made of an alloy containing niobium in the range of 2 to 4% by weight, preferably in the range of 2.5 to 3.5% by weight, and especially preferably in the range of 2.8 to 3.2% by weight. In particular, the alloy of the magnetic field-sensitive element contains niobium in a proportion of 3% by weight.

[0118] In particular, the magnetic field-sensitive element is made of an alloy containing boron in the range of 5 to 9% by weight, preferably 6 to 8% by weight, and especially preferably 6.5 to 7.5% by weight. In particular, the alloy of the magnetic field-sensitive element contains boron in a proportion of 7% by weight.

[0119] In particular, the magnetic field-sensitive element is made of an alloy containing silicon in the range of 14 to 17% by weight, preferably in the range of 15 to 16% by weight, and especially preferably in the range of 15.4 to 15.6% by weight. In particular, the alloy of the magnetic field-sensitive element contains silicon in a proportion of 15.5% by weight.

[0120] It should be clearly stated that the above values ​​for the alloy composition of the magnetic field-sensitive element should not be understood as definite limits, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the described aspects of the present invention.

[0121] In particular, the magnetic field-sensitive element is preferably made of a nanocrystalline soft magnetic material having a typical particle size in the range of 5 to 30 gm, preferably a nanocrystalline soft magnetic material having a typical particle size in the range of 7 to 20 gm, or a nanocrystalline soft magnetic material having a typical particle size in the range of 8 to 15 gm.

[0122] In particular, according to Maxwell's equations, eddy current losses in magnetically sensitive elements can be kept low in this way, and therefore, magnetically sensitive elements are fabricated from strips with particularly small thicknesses.

[0123] In particular, the magnetic field-sensitive element has a band thickness in the range of 5 to 50 gm. The band thickness of the magnetic field-sensitive element is preferably in the range of 7.5 to 40 gm, and particularly preferably in the range of 10 to 30 gm.

[0124] It should be clearly stated that the above values ​​for the band thickness of the magnetic field-sensitive element should not be understood as a definite limit, but rather should be able to exceed or fall below it on an engineering scale without departing from the embodiments of the invention described herein. Simply put, the values ​​should provide an indicator of the magnitude of the band thickness of the magnetic field-sensitive element proposed herein.

[0125] In particular, the cross-sectional area of ​​the iron in the magnetic field-sensitive element is 0.03~0.15 cm². 2 This is within the range. Furthermore, the cross-sectional area of ​​the iron in the magnetic field-sensitive element is preferably 0.04 to 0.12 cm². 2 This range is particularly preferred. The cross-sectional area of ​​the iron in the magnetic field-sensitive element is 0.05 to 0.1 cm². 2 It is within the range of [the specified range].

[0126] In particular, the magnetic field-sensitive element has a height of 3 to 7 mm, preferably 3.4 to 6.6 mm, and especially preferably 3.8 to 6.2 mm.

[0127] It should be clearly stated that the above values ​​for the cross-sectional area of ​​the iron and the height of the magnetic field-sensitive element should not be understood as definite limits, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the embodiments of the invention described herein. In short, these values ​​should provide indicators of the size of the cross-sectional area of ​​the iron and the height of the magnetic field-sensitive element proposed herein.

[0128] In particular, it is proposed that the sensor determine the residual current according to the operating principle of the Förster probe.

[0129] In particular, the number of windings of the first main winding are arranged at equal intervals around the entire circumference of the magnetic field-sensitive element.

[0130] In particular, the first main winding has a number of turns in the range of 25 to 150 turns, preferably in the range of 35 to 135 turns, and especially preferably in the range of 40 to 130 turns. Furthermore, in particular, the first main winding has a number of turns in the range of 45 to 125 turns, preferably in the range of 50 to 120 turns, and especially preferably in the range of 60 to 110 turns.

[0131] Advantageously, the proposed number of turns in the first main winding allows for winding the magnetic field-sensitive elements at as equal a distance as possible between individual windings, in order to generate a magnetic flux density as locally uniform as possible in the magnetic field-sensitive elements when the first main winding is energized.

[0132] It should be made clear that the above values ​​for the number of turns of the first main winding should not be understood as definite limits, but rather should be able to exceed or fall below them on an engineering scale without departing from the embodiments of the invention described herein. In short, these values ​​should provide an index of the magnitude of the number of turns of the first main winding proposed herein.

[0133] In particular, the number of turns in the test winding are arranged at equal intervals around the entire circumference of the magnetic field-sensitive element.

[0134] In particular, the test winding has a number of turns in the range of 3 to 40 turns, preferably in the range of 4 to 35 turns, and especially preferably in the range of 5 to 30 turns. Furthermore, in particular, the test winding has a number of turns in the range of 6 to 25 turns, preferably in the range of 8 to 22 turns, and especially preferably in the range of 10 to 18 turns.

[0135] Advantageously, since the test windings are spaced equally apart and can be uniformly distributed across the entire magnetic field-sensitive element, the proposed number of turns in the test windings allows for particularly accurate determination of the magnetic flux density of the magnetic field-sensitive element due to the inductive effect it produces on the test windings.

[0136] It should be clearly stated that the above values ​​for the number of turns of the test winding should not be understood as a strict range, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the described aspects of the invention. Simply put, these values ​​should provide an index of the magnitude of the number of turns of the test winding proposed herein.

[0137] The proposed range of through-apers for the magnetic field-sensitive element, when the shielding is ideally functionally designed, results in an inner dimension of the through-aper of the shielding in the range of 18.2 to 30 mm, preferably in the range of 19.5 to 27.5 mm, and particularly preferably in the range of 20.5 to 24.2 mm. Particularly preferably, the inner dimension of the through-aper of the shielding is in the range of 20.8 mm to 22.2 mm.

[0138] It should be clearly stated that the above values ​​for the range of the internal dimensions of the through-opening of the shielding body should not be understood as a strict range, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the described aspects of the present invention. Simply put, these values ​​should provide an index of the size of the individually proposed range for the internal dimensions of the through-opening of the shielding body.

[0139] Needless to say, the specified range limits for internal dimensions can be combined in any way.

[0140] In a preferred embodiment, the magnetic susceptible element is covered with an insulator, which is placed between the magnetic susceptible element and the first main winding, and between the magnetic susceptible element and the test winding.

[0141] In this regard, let me explain the following terms: An "insulator" is understood to be an element made of a material with particularly low conductivity, and therefore conducts only a very small amount of electric current compared to the surrounding material.

[0142] In particular, the insulator is formed in two parts, so that it can be opened to accommodate the magnetic field-sensitive element and then closed again.

[0143] A two-part insulator has a shape bond and / or force bond between the two parts of the insulator, so that it can advantageously and reliably surround a magnetic field-sensitive element, preventing it from unintentionally opening and / or releasing the magnetic field-sensitive element again.

[0144] In particular, it is preferable that the insulator has a lower hardness than the winding material, and as a result, any friction that may occur between the insulator and the winding will, advantageously, damage the insulator rather than the winding.

[0145] The insulator advantageously allows for the regional isolation of the magnetic field-sensitive element from the first main winding and test winding, and possibly the second main winding, thereby reducing potential winding damage.

[0146] If the insulator has low hardness and / or a low modulus of elasticity as the material for the first main winding and test winding, and possibly the second main winding, a preload (Vorspannkraft) can be set on the winding to allow for elastic deformation of the insulator and thus shape bonding between the insulator and the winding, so that the winding is better positioned relative to the other winding, thereby advantageously improving the reliability of the sensor.

[0147] Furthermore, the insulator allows the distance between the winding and the magnetic field-sensitive element to remain constant. This advantageously ensures that the physical connection between the winding and the magnetic field-sensitive element remains constant. Therefore, the accuracy of sensor signal determination can be advantageously and permanently maintained.

[0148] Preferably, the sensor has a second main winding, the second main winding surrounding a magnetosensitive element and / or insulator with a plurality of windings.

[0149] In this regard, let me explain the following terms: The "second main winding" is understood to be a main winding wound around the magnetic field-sensitive element, in addition to the first main winding.

[0150] In particular, the second main winding has a winding direction different from that of the first main winding.

[0151] In a specified operation of a sensor according to a first embodiment of the present invention, which has a first main winding but no second main winding, an AC voltage is supplied to the first main winding, and each time the sign of the supplied voltage changes, the sign of the current flow in the first main winding is reversed.

[0152] Instead, a current source is supplied to the first main winding, alternating the direction of the current. By using this current source, higher measurement accuracy of the sensor can be advantageously achieved.

[0153] In other words, the first main winding has a periodic flow of current in different directions during the specified operation of the sensor.

[0154] The time profile of the current flow in the first main winding during specified sensor operation may have a sinusoidal, rectangular, or other vibrational shape.

[0155] The current flow oscillating in the first main winding is set to induce a magnetic flux density that oscillates similarly in the magnetic field-sensitive element.

[0156] The sensor proposed here has two main windings, namely a first main winding and a second main winding.

[0157] Preferably, the number of turns of the second main winding is equal to the number of turns of the first main winding.

[0158] This makes it possible for a single main winding not to need to change the sign of the current flow direction in order to operate the sensor as specified. Rather, the two main windings can each be operated in a pulsed manner, so that they alternate between having current flow and not having current flow.

[0159] When two main windings are wound around a magnetic field-sensitive element in different directions of rotation, the two main windings can be alternately connected to the same voltage or current source, allowing the voltage or current source to have a steady, constant output value, thereby inducing an AC magnetic flux density in the magnetic field-sensitive element. This also advantageously enables a more favorable design of the operating circuit for the specified sensor operation. This allows for a reduction in the common cost of the sensor and operating circuit, even if additional main windings are required.

[0160] In particular, the number of windings of the second main winding are arranged at equal intervals around the entire circumference of the magnetic field-sensitive element.

[0161] In particular, the second main winding has a number of turns in the range of 25 to 150 turns, preferably in the range of 35 to 135 turns, and especially preferably in the range of 40 to 130 turns. Furthermore, in particular, the second main winding has a number of turns in the range of 45 to 125 turns, preferably in the range of 50 to 120 turns, and especially preferably in the range of 60 to 110 turns.

[0162] Advantageously, the number of turns of the second main winding proposed here makes it possible to wind the individual windings around the magnetic field-sensitive element at as equal intervals as possible, so that when the second main winding is energized, a magnetic flux density as locally uniform as possible is generated around the magnetic field-sensitive element.

[0163] It should be made clear that the above values ​​for the number of turns of the second main winding should not be understood as a strict range, and should be able to exceed or fall below these values ​​on an engineering scale without departing from the described aspects of the present invention. In short, these values ​​should provide an indicator of the magnitude of the number of turns of the second main winding proposed herein.

[0164] In particular, according to a purposeful embodiment, the sensor has a spacer ring, which is positioned between the inner wall of the shield and the first main winding.

[0165] In this regard, let me explain the following terms: A "spacer ring" is understood to be a ring-shaped element positioned between the inner wall of the shielding and the first main winding of the sensor.

[0166] In particular, the spacer ring is configured to reduce or fill the radial gap in the accommodating space between the inner wall of the shielding and the main winding.

[0167] In particular, the spacer ring is set to fill the axial gap between the first shielding portion and the second shielding portion, so that as soon as the two shielding portions are placed in contact with the spacer ring, the spacer ring can define the width of the circumferential gap.

[0168] In particular, the spacer ring is made of plastic or another material having a relatively low specific conductivity.

[0169] Advantageously, the spacer ring can also achieve protection of the main winding and / or test winding wires during sensor assembly. The spacer ring can be inserted, along with the main winding or multiple main and test windings already wound around the magnetic field-sensitive element, particularly into the first part of the shield, especially into the part of the shield, particularly into the part of the other part of the shield that overlaps at least partially on its outer surface. Thus, the magnetic field-sensitive element can be carefully inserted into the first part of the shield under visual supervision, and the magnetic field-sensitive element is protected from mechanical loads inside by the spacer ring, in particular the windings arranged around the magnetic field-sensitive element are protected from mechanical loads inside by the spacer ring. Subsequently, the second part of the shield can be fitted so that the windings are already protected from mechanical loads by the overlapping first part of the shield with the spacer ring. To that extent, the spacer ring can advantageously improve the mechanical protection of sensitive components, even when visual access to particularly sensitive components is not possible during the assembly of the second part of the shield.

[0170] Preferably, a spacer ring is proposed having an insert made of a material having a relatively high permeability, particularly a permeability substantially equivalent to that of the shielding material, within its base material. In particular, the insert is completely surrounded by the base material of the spacer ring so that it is insulated by a base material having a relatively low conductivity.

[0171] This advantageously reduces leakage of the magnetic field generated from the magnetic field-sensitive element in the circumferential gap during the specified operation of the sensor, as a result of the high permeability of the spacer ring. This also advantageously improves the measurement accuracy of the sensor and reduces the energy consumption of the sensor.

[0172] Optionally, the shielding material may have a coating, particularly an electrical insulating coating.

[0173] In this regard, let me explain the following terms: "Coating" is understood as a fixed layer made of an indeterminate substance on the surface of a shielding material.

[0174] In particular, the coating is designed to conduct electric current particularly poorly. Therefore, the coating has particularly low conductivity.

[0175] In particular, the coating is preferably made of epoxy resin.

[0176] In particular, the coating is provided on the shield so as to cover at least a portion of the outer shield surface that is specified and positioned near the printed circuit board.

[0177] Advantageously, this method makes it possible to achieve insulation of the shielding material from the designated circuit board, thereby advantageously preventing short circuits between the shielding material and the designated circuit board.

[0178] According to a purposeful embodiment, the shielding body has a material thickness in the range of 0.25 mm to 0.45 mm, preferably in the range of 0.3 mm to 0.4 mm, and particularly preferably in the range of 0.32 mm to 0.38 mm.

[0179] In this regard, let me explain the following terms: "Material thickness" or material thickness is understood as the extent of an object in the direction of the surface normal.

[0180] Eddy currents are understood as electric currents induced in an electrical conductor that expands in a magnetic field that changes over time, and / or in a conductor that moves in a magnetic field that is constant over time but spatially non-uniform. If the conductor has a finite electrical resistance, the conductor is heated as a result of eddy currents. The amount of energy converted into this heat is called "eddy current loss."

[0181] Here, it is proposed to reduce the material thickness of the shielding material for the magnetic field-sensitive element, along with at least one main winding and the test winding around the magnetic field-sensitive element.

[0182] The possibility of reducing the material thickness in the shielding area is based on innovations in the field of shielding manufacturing.

[0183] In particular, the shielding material is deep-drawn or injection-molded.

[0184] This also allows for cost reductions compared to cases where the shielding material is thicker.

[0185] During the specified operation of the sensor, the magnetic field-sensitive element has an oscillating magnetic flux density. Since the shielding material is also made of a material with good conductivity, the change in the magnetic flux density of the magnetic field-sensitive element exerts an inductive effect on the shielding material. This inductive effect is undesirable because it causes eddy current losses.

[0186] By reducing the material thickness of the shielding, eddy current losses that occur during the specified operation of the sensor can be advantageously reduced.

[0187] This allows for a significant reduction in the sensor's energy consumption and improves the sensor's measurement accuracy.

[0188] It should be made clear that the above values ​​for the material thickness of the shielding body should not be understood as a strict range, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the described aspects of the present invention. In short, these values ​​should provide an index of the magnitude of the material thickness of the shielding body proposed herein.

[0189] Preferably, the circumferential gap has a gap width in the range of 0.1 mm to 2.0 mm, preferably in the range of 0.3 mm to 1.7 mm, and particularly preferably in the range of 0.6 mm to 1.3 mm.

[0190] In this regard, let me explain the following terms: "Gap width" is understood to mean the width of the gap. In particular, the gap width is understood to mean the width of the gap extending circumferentially on the inner wall of the shielding material.

[0191] A circumferential gap in the shielding is particularly advantageous. This is because, otherwise, the shielding would also act as a winding made of a highly conductive material around the magnetic field-sensitive element, which would exert a relatively strong inductive effect during the specified operation of the sensor where the magnetic flux density oscillates in the magnetic field-sensitive element. This would increase eddy current losses in relation to the shielding, which could lead to increased energy consumption of the sensor and a decrease in the measurement accuracy of the sensor.

[0192] However, the circumferential gaps in the sensor's shielding, in particular, have a significantly lower magnetic permeability of the air within them compared to the shielding itself, which also leads to a decrease in the magnetic field around the magnetic field-sensitive element.

[0193] Therefore, if the width of the circumferential gap is too large, various physical effects will occur, which in turn will negatively impact the sensor's energy consumption and measurement accuracy.

[0194] Therefore, a specific range of circumferential gap widths is proposed here, thereby advantageously achieving an optimal state between the optimal measurement accuracy of the sensor when the circumferential gap width is too small and when the circumferential gap width is too large, based on different physical effects.

[0195] Furthermore, the width of the circumferentially extending gap proposed here may allow for a favorable minimization of the energy consumption required for sensor operation.

[0196] It should be made clear that the above values ​​for the gap width of the circumferentially extending gap should not be understood as strict limits, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the described aspects of the present invention. In short, these values ​​should provide an index of the magnitude of the gap width of the circumferentially extending gap proposed herein.

[0197] According to a purposeful embodiment, the sensor has an electrical connector, the electrical connector having a support plate, a connector neck, and a plurality of electrical contacts. - The electrical connector has at least two electrical contacts per winding. -The electrical contacts are arranged radially on the outside of the shielding's outer wall. - The support plate is positioned between the outer wall of the shielding body and the first main winding. - The connector neck extends through an opening in the outer wall of the shielding body, connecting the support plate and the electrical contacts to each other. - The support plate and connector neck each have corresponding cavities, which are configured to receive the two wires that are operationally connected to each winding from the housing space and to pass them from the housing space through the opening in the shielding to the electrical contacts. - The cavity has a notch parallel to the outer wall of the shielding body, through which the electric wire can be inserted into the central area of ​​the cavity.

[0198] In this regard, let me explain the following terms: An "electrical connector" is understood to be an element that is configured to be attached to a sensor and has at least the required number of accessible electrical contacts.

[0199] In particular, the connector allows the electrical and / or electronic components (Bauelement) of the sensor to be electrically connected to the electrical contacts of the connector, and the electrical contacts of the connector have relatively good accessibility.

[0200] In particular, the connector preferably allows the electrical contacts to be positioned in a fixed location relative to the sensor, at least indirectly.

[0201] Therefore, overall, the connector particularly and advantageously enables the use of the sensor with a fixed relative arrangement between the magnetic field-sensitive element and the electrical contacts, and allows the sensor's electronic and / or electrical elements to be electrically connected to the electrical contacts at the time of manufacturing the sensor.

[0202] Therefore, the sensor can be advantageously connected to the substrate either directly by soldering or indirectly via other contact elements, particularly a plug, through the electrical contacts of an electrical connector, so that the relative position of the magnetic field-sensitive element to the substrate can be fixed by connections made at least indirectly by the electrical connector.

[0203] In particular, electrical connectors have plastic as their base material, especially plastics with relatively low conductivity.

[0204] In particular, the electrical contacts of an electrical connector are at least partially surrounded by the connector's base material, thereby creating a force-coupled and / or shape-coupled connection between the base material and the electrical contacts. Furthermore, in particular, the electrical contacts are spatially separated from each other by the base material of the electrical connector, which advantageously prevents direct electrical contacts between two electrical contacts, thereby preventing short circuits between individual electrical and / or electronic elements of the sensor.

[0205] The term "support plate" is understood to mean the region of an electrical connector that is configured to connect the magnetic field-sensitive element to the electrical connector at least indirectly, by shape coupling and / or force coupling.

[0206] In particular, the support plate can be housed within the accommodating space of the shielding body, especially between the shielding body and the main winding, and especially between the main winding and the outer wall of the shielding body.

[0207] In particular, the support plate is preferably configured to be inserted into the shielding together with the magnetic field-sensitive element and the winding surrounding the magnetic field-sensitive element. This is advantageous because the support plate provides additional protection for the winding from mechanical loads when it is assembled into the shielding.

[0208] The term "connector neck" is understood to refer to the area of ​​an electrical connector where the support plate and electrical contacts are configured to connect to each other.

[0209] An "electrical contact" is understood to be an element of an electrical connector that is configured to make contact between the electrical and / or electronic components of a sensor.

[0210] In particular, the electrical contacts are formed such that they protrude in two directions from the base material of the electrical connector. In this case, it should be kept in mind that contact between the electrical and / or electronic components of the sensor and the electrical contacts can be made at the protruding ends of the contacts. Furthermore, it should be kept in mind that contact with the operating circuit of the sensor can be made at different protruding ends of the electrical contacts, particularly by soldering, or by plug connectors corresponding to one or more electrical contacts.

[0211] In particular, the electrical contacts are made of an alloy containing nickel in the range of 17 to 19% by weight, preferably in the range of 17.5 to 18.5% by weight, and especially preferably 18% by weight.

[0212] In particular, the electrical contacts are made of an alloy containing 18-22% by weight of zinc, preferably 19-21% by weight of zinc, and especially preferably 20% by weight of zinc.

[0213] In particular, the electrical contacts are made of an alloy containing 58% by weight or more copper, preferably 60% by weight or more copper, and especially preferably 61% by weight or more copper. Furthermore, preferably the electrical contacts are made of an alloy containing 62% by weight or more copper, even more preferably 63% by weight or more copper, and especially preferably 64% by weight or more copper.

[0214] The aforementioned alloy composition for electrical contacts is advantageous in that it allows for a relatively high elastic modulus and very good dipping tin plating and soldering properties, as well as very good electrical conductivity.

[0215] It should be clearly stated that the above values ​​regarding the alloy composition of electrical contacts should not be understood as definite limits, but rather should be able to exceed or fall below these values ​​on an engineering scale without departing from the embodiments of the invention described herein. Simply put, these values ​​should provide an index of the magnitude of the alloy composition of electrical contacts proposed herein.

[0216] In particular, the electrical contacts have a gold coating, which advantageously improves the conductivity of the electrical contacts.

[0217] An "opening" is understood to be a region in a shielding body through which the connector neck of an electrical connector, which connects a support plate and electrical contacts to each other, can extend from the housing space inside the shielding body to the region outside the shielding body, thereby allowing the electrical contacts of the electrical connector to be positioned outside the shielding body. For this purpose, the shielding body has an opening, in particular, corresponding to the connector neck.

[0218] In the case of a two-part shielding body, it should be kept in mind that one or both parts of the shielding body may have a cavity that forms an opening after the parts of the shielding body are joined together.

[0219] In particular, the opening is located within the area of ​​the outer wall of the shielding body.

[0220] A "void" is understood to be a region in the cross-section of an element that is not formed by the element's substrate and therefore can be penetrated by other objects without damaging the element.

[0221] In particular, the voids are channels through which the component's substrate passes.

[0222] Furthermore, the void is formed in the form of a recess in the base material of the component, thereby allowing another object to be inserted into the void through the opening of the recess.

[0223] The "corresponding voids" in the connector neck and support plate are understood to mean that the void extends through both the support plate and the connector neck with a substantially constant contour shape in the main direction of the void's extension.

[0224] Electric wire is understood to be a thin, flexible metal wire in the longitudinal direction. In particular, electric wire has a circular cross-section. In particular, electric wire has multiple strands. In particular, electric wire has a high proportion of copper.

[0225] A "notch" is understood to be a pointed or wedge-shaped incision.

[0226] A sensor according to a first aspect of the present invention has a plurality of electrical and / or electronic components. During a specified operation of the sensor, an electric current is generated in or actively supplied to the electronic and / or electrical components.

[0227] These electrical and / or electronic components of the sensor must be positioned within the designated enclosure space and electrically connected from the outside of the enclosure.

[0228] The simplest form of electrical contact is based on the idea that wires connected to electrical and / or electronic components are routed through a shield to the outside, where they are soldered to a circuit board containing the sensor's operating circuitry.

[0229] This solution presents numerous different sources of damage to the wires, and therefore the sensor as a whole, which could lead to sensor failure. On the one hand, wires, which in most cases have very small conductor cross-sections, can easily break due to mechanical loads, particularly shear loads in the shielding area, or tensile loads between windings and at the connections between the wires and the circuit board. Such tensile loads can occur during sensor assembly or even during sensor operation, when there is relative motion with the magnetic field-sensitive element and contact between the wires and the circuit board.

[0230] Here, it is proposed to make the sensor's wires mechanically and electrically connectable using electrical connectors, thereby advantageously improving the robustness and availability of the sensor.

[0231] The electrical connector proposed herein has a support plate positioned within the accommodating space of a shielding body. A connector neck extends from the support plate as a second region of the electrical connector. The connector neck extends particularly through the shielding body, and especially in the region of the outer wall of the shielding body. Multiple electrical contacts, configured to make electrical contact with the electrical and / or electronic components of a sensor, are connected to the connector neck.

[0232] The support plate enables force-coupled and / or shape-coupled connections between the electrical connector and the sensor, particularly with the sensor's shielding.

[0233] The connector neck is designed to accommodate the wire and therefore protect it from mechanical loads, particularly in the area of ​​the shielding. For this purpose, the connector neck and support plate have corresponding cavities into which the wire can be inserted and which protect the wire from external mechanical loads.

[0234] Furthermore, the connector neck fixes the relative position between the sensor's magnetic field-sensitive element and the electrical contacts that are set to make electrical contact. The wire can be routed through the corresponding cavities in the connector neck and support plate to the electrical contacts, where it can make contact with the electrical contacts.

[0235] The corresponding cavities in the connector neck and support plate are shaped like troughs that open laterally to the longitudinal direction of the corresponding cavities, thereby allowing wires to be inserted into the cavities not only longitudinally but also laterally relative to the longitudinal direction. This design enables advantages in sensor assembly because the wires can be inserted sequentially and bundled together both longitudinally and laterally, significantly simplifying the installation of wires into the cavities.

[0236] The corresponding cavities in the connector neck and support plate have notches extending laterally with respect to the longitudinal axis of the corresponding cavities, with the tip of the notch pointing toward the cavities. The notches allow for easy lateral insertion of individual wires or bundles of wires into the cavities, while ensuring that each wire can pass through the narrow portion of the notch. The narrow portion of the notch is designed so that once a wire is inserted into the cavity, it can only be removed from the cavities laterally with greater effort, thereby remaining within the designated protected area of ​​the cavities. This simplifies the assembly of the wires and ensures that the wires are protected, in particular, from mechanical loads after insertion into the cavities.

[0237] According to a second aspect of the present invention, a protective circuit breaker for shutting off a circuit when a residual current exceeding a limit value occurs in the circuit, comprising a sensor according to the first aspect of the present invention, an operating circuit, an electronic data processing and evaluation unit, and a switching device, - The sensor is positioned around at least two electrical conductors that form a circuit. - The switching device is set to interrupt the circuit. -The operating circuit is configured to activate the sensor, - The electronic data processing and evaluation unit is configured to evaluate the sensor signal of the sensor, - The electronic data processing and evaluation unit solves the problem by having a protective circuit breaker configured to drive the switching device at a current intensity greater than a limit value, particularly an adjustable limit value, so that the switching device interrupts the circuit when residual current is detected, especially when residual current is detected in a bicurrent-sensitive manner.

[0238] In this regard, let me explain the following terms: A "protective circuit breaker" is understood to be a device that is configured to shut down the voltage of a monitored circuit when a predetermined residual current is exceeded, particularly when an adjustable residual current is exceeded. In this way, the risk of residual current to people and infrastructure can be advantageously reduced.

[0239] The "operating circuit" is understood to be the circuit for the active or passive operation of the sensor. In particular, the operating circuit is configured to supply voltage to the first main winding and / or the second main winding of the sensor.

[0240] Furthermore, the operating circuit is configured to extract voltage, particularly from the sensor's test winding, and transfer it as a signal to the data acquisition and evaluation unit (Datenerfassungs-und-auswerteeinheit).

[0241] Similarly, the operating circuit is also configured to extract voltage, in particular, from the first and / or second main windings of the sensor and transfer it as a signal to the data acquisition and evaluation unit.

[0242] In particular, it should be kept in mind that the operating circuit may also have a power consumption measuring device configured to evaluate the power consumption of the test winding and / or the first main winding and / or the second main winding.

[0243] An "electronic data processing and evaluation unit" is an electronic unit that organizes and handles large amounts of data, and in doing so, pursues the goal of acquiring information about this large amount of data or modifying data in this manner. In this case, the data is compiled in the form of a dataset, processed by a person or machine in a predetermined manner, and output as a result.

[0244] "Data" is understood to mean, in particular, measured values, especially sensor signals, or other physical or chemical measured values ​​or quantities.

[0245] A "switching device" is understood to be a device configured to shut down the voltage supply to a circuit, particularly a circuit breaker.

[0246] A "circuit" is understood as an electrical circuit consisting of a conductor with a diameter that represents a closed path.

[0247] A "sensor signal" is understood to be a state quantity provided by a sensor. In particular, the sensor signal is configured so that it can be inferred from the sensor signal by the physical and / or chemical dependence of the residual current of the circuit being monitored by the sensor. In particular, the residual current monitored by the sensor can be calculated directly from the sensor signal. In particular, the sensor signal is a determinable current intensity and / or a determinable voltage.

[0248] "Current intensity" is understood as the measurement of electric current, particularly the current in an electrical circuit, in the form of a physical quantity. In this case, current intensity is related to a properly oriented surface, especially the cross-section of an electrical conductor. In this context, current intensity is the amount of charge that flowed through the cross-section and was observed over a given period of time.

[0249] In particular, the sensor signal is understood to be the power consumption of the first main winding, which can be converted into residual current by mathematical rules.

[0250] The term "limit value" is understood to be a defined value of residual current, particularly a state quantity that, if exceeded in a circuit monitored by a protective circuit breaker, requires the switching device to shut down the voltage supply to the monitored circuit at the latest by the protective circuit breaker. In particular, the limit value of a circuit breaker may be adjustable.

[0251] In other words, a circuit breaker that utilizes a sensor according to a first aspect of the present invention for monitoring a circuit is specifically proposed here.

[0252] Needless to say, the advantages of the sensor for determining residual current according to the first aspect of the present invention also directly apply to protective circuit breakers having a protective circuit breaker according to the first aspect of the present invention, as described above.

[0253] This advantageously enables the creation of a protective circuit breaker with particularly high sensitivity to residual current, thereby allowing the circuit breaker to interrupt the circuit even when the residual current in the monitored circuit is very small. Furthermore, in this case, it is also advantageously achieved that the protective circuit breaker is particularly unlikely to mistakenly detect a residual current that would inadvertently exceed the limit current when the monitored circuit is turned on.

[0254] It should be clearly stated that the subject matter of the second embodiment can be combined with the subject matter of the preceding embodiments of the present invention individually or in any combination to be cumulatively advantageous.

[0255] According to a third aspect of the present invention, a charging cable for charging an electric vehicle, wherein the charging cable has a sensor according to the first aspect of the present invention and / or a protective circuit breaker according to the second aspect of the present invention, solves the problem.

[0256] In this regard, let me explain the following terms: A "charging cable" is understood to be an electrical connection configured to connect an electric vehicle to a power source, in this case, the charging cable is configured to charge the traction battery of the electric vehicle. In particular, the charging cable may have a device to monitor any residual current present.

[0257] An "electric vehicle" is understood to be a vehicle that is driven at least partially by an electric motor. In particular, an electric vehicle is not bound to a track, or at least not permanently bound to a track.

[0258] Herein, a charging cable for charging an electric vehicle battery is proposed, having a protective circuit breaker according to a second aspect of the present invention and / or a sensor according to a first aspect of the present invention.

[0259] Needless to say, the advantages of the sensor for determining residual current according to the first aspect of the present invention, and / or the protective circuit breaker for interrupting a circuit when residual current occurs in the circuit, directly apply to a charging cable for charging an electric vehicle, which has the sensor according to the first aspect of the present invention and / or the protective circuit breaker according to the second aspect of the present invention, as described above.

[0260] It should be clearly stated that the subject matter of the third embodiment can be advantageously combined with the subject matter of the preceding embodiments of the present invention individually or in any combination.

[0261] According to a fourth aspect of the present invention, a charging station for charging an electric vehicle is provided, which has a sensor according to the first aspect of the present invention and / or a circuit breaker according to the second aspect of the present invention.

[0262] In this regard, let me explain the following terms: A "charging station" or "wall charging station" is understood to be a charger for charging electric vehicles. In the case of a wall charging station, the charging station is specifically designed to be mounted on a wall. In particular, a charging station is a mobile device that can be installed in various locations. In particular, a charging station or wall charging station provides other functions, in particular a device for monitoring residual current, which may occur, in addition to plugging in charging cables to connect the charging station to an electric vehicle and to a power supply network.

[0263] Herein, a charging station for charging electric vehicles is proposed, having a protective circuit breaker according to a second aspect of the present invention and / or a sensor according to a first aspect of the present invention.

[0264] Needless to say, the advantages of the sensor for determining residual current according to the first aspect of the present invention, and / or the protective circuit breaker for interrupting a circuit when a residual current exceeding a limit value occurs in the circuit, as described above, directly apply to charging stations for charging electric vehicles that have the sensor according to the first aspect of the present invention and / or the protective switch according to the second aspect of the present invention.

[0265] It should be made clear that the subject matter of the fourth aspect can be combined with the subject matter of the preceding aspects of the present invention individually or in any combination to be cumulatively advantageous. Other advantages, details, and features of the present invention will become apparent from the embodiments described below. [Brief explanation of the drawing]

[0266] [Figure 1] Figure 1 is a schematic diagram showing the configuration of the sensor according to the present invention in the circuit. [Figure 2] Figure 2 is a schematic diagram showing the physical action coupling when the circuit is turned on. [Figure 3] Figure 3 schematically shows the dynamic change in magnetic flux density over time when the circuit at an exemplary location in a magnetic field-sensitive element is turned on. [Figure 4] Figure 4 schematically shows the physical relationship between the internal width of the magnetic field-sensitive element, the profile of the sensor malfunction tendency dependent on the internal width, and the profile of the minimum measurable residual current of the sensor dependent on the internal width. [Figure 5] Figure 5 is a schematic cross-sectional view of the sensor according to the present invention. [Figure 6] Figures 6a to 6g are schematic diagrams of electrical connectors. [Modes for carrying out the invention]

[0267] In the following description, the same reference numerals indicate the same part or feature, and therefore descriptions made with reference to the figures also apply to other figures, thereby avoiding repetition of descriptions. Furthermore, individual features described in relation to one embodiment can also be used separately in other embodiments.

[0268] The sensor 100, schematically shown in Figure 1, is arranged around electrical conductors 110 and 120, through which the specified currents 112 and 114 flow into and out of a circuit (not shown) monitored by the sensor 100.

[0269] In that case, the current 112 flows through the outer conductor 110 into a circuit (not shown) monitored by the sensor 100, and flows out again through the neutral conductor 120.

[0270] When the voltage source (not shown) in the circuit (not shown) is turned on, a dynamic physical coupling occurs between the magnetic fields 114 and 124 generated around the electrical conductors 110 and 120 and the regional magnetic flux densities 116 and 118 in the magnetic field-sensitive element 10, as shown in Figure 2.

[0271] When the voltage source (not shown) is turned on, the magnetic fields 114 and 124, originating from the electric conductors 110 and 120, exert various effects on the magnetic field-sensitive element 10 in a region and time-limited manner, thereby generating magnetic flux densities 116 and 126 in the magnetic field-sensitive element 10 in a region and for a short period of time.

[0272] It is observed that the transient and locally reversed magnetic flux densities 116 and 126 in the magnetic field-sensitive element 10 result in a dynamic behavior of the magnetic flux density in the form of oscillations of the magnetic flux density 132 during its compensation process in Figure 3 for time 130 at an exemplary location (not shown) in the magnetic field-sensitive element 10.

[0273] This oscillation of magnetic flux density 132, resulting from turning on a current source (not shown) for the observed circuit (not shown), decays and approaches its time limit along the asymptotes 132, 134.

[0274] In that case, the short-time vibration of the magnetic flux density 132 leads to a physical interaction (not shown) with a test winding (not shown) and / or the first main winding and / or the second main winding, thereby generating a sensor signal (not shown), which can be interpreted as a residual current (not shown) exceeding a defined limit value (not shown). This can also be described as a switch-on error (Einschaltfehler).

[0275] The relationship between the inner width 12 of the through-opening (not shown) of the magnetic field sensor element 10 shown in FIG. 4, the tendency of a malfunction 140 of a protective circuit breaker (not shown) specified for use with the sensor 100, and the minimum residual current 150 measurable with the sensor 100 indicates that there is an optimum value 160 for the inner width 12 of the through-opening (not shown) of the magnetic field sensor element 10, at which a good compromise is found between the measurable minimum residual current 150 and the tendency of the malfunction 140.

[0276] This optimum value 160 is located at the intersection of the profiles 142, 152 in the observation of the figures presented here.

[0277] Furthermore, an optimum range 165 for the inner width 12 of the through-opening (not shown) of the magnetic field sensor element 10 becomes apparent, which is arranged around the optimum value 160.

[0278] The sensor 100 in FIG. 5 consists substantially of a magnetic field sensor element 10, an insulator 20 surrounding the magnetic field sensor element 10, a main winding 30, a test winding (not shown), a spacing 40, a shielding 50, an electrical connector 60, and a plurality of electrical contacts ,

[0279] The insulator 20 is formed in a two-part configuration, and the individual parts (not shown) of the insulator 20 are connected to each other in a form-fitting manner.

[0280] The main winding 30 is connected by an electric wire 75 to an electric contact 70 supported by the electric connector 60.

[0281] The shielding body 50 is formed in a two-part structure and forms a gap 55 extending in the circumferential direction on the inner wall 58 of the shielding body.

[0282] The electrical connector 60 in Fig. 6 substantially consists of a support plate 80, a connector neck 90, and a plurality of electrical contacts 70.

[0283] Fig. 6b) shows a three-dimensional view of the electrical connector 60.

[0284] Fig. 6a) shows a front view of the electrical connector 60, which is a view seen from the outside with respect to the designated sensor.

[0285] Fig. 6c) shows a top view of the electrical connector 60. Further, cutting lines A-A and B-B are shown.

[0286] Fig. 6d) shows a cross-section A-A of the electrical connector 60.

[0287] Fig. 6e) shows a cross-section B-B of the electrical connector 60.

[0288] Fig. 6f) shows a front view of the electrical connector 60, which is a view seen from the inside with respect to the designated sensor.

[0289] Fig. 6g) shows a side view of the connector 60.

[0290] The support plate 80 is set to be accommodated in an accommodation space (not shown) of a shielding body (not shown).

[0291] The connector neck 90 connects the plurality of electrical contacts 70 to the support plate 80.

[0292] The connector neck 90 has a cavity 92 set to receive two electric wires (not shown) that are operatively coupled to each winding (not shown) from an accommodation space (not shown) and pass through an opening (not shown) of the outer wall of the shielding body (not shown) to the electrical contacts (70) from the accommodation space (not shown).

[0293] The void 92 further has a notch 94 in a direction parallel to the outer wall of the shield (not shown), and through this notch, an electric wire (not shown) can be installed in the central region (not shown) of the void 92.

[0294] Through the notch 94, an electric wire (not shown) can be individually or bundled and easily inserted laterally into the void 92. In that case, the notch 94 must be passed through by each electric wire (not shown) at its narrow portion (not shown). The narrow portion (not shown) of the notch 94 cannot be withdrawn from the void 92 laterally with respect to the longitudinal direction (not shown) of the void 92 without great effort once the electric wire (not shown) is installed in the void 92, and thus remains within the designated protection region (not shown) of the void 92.

Explanation of Signs

[0295] 10 Magnetic field sensitive element 12 Inner flange width 20 Insulator 30 Main winding 40 Spacering 50 Shield 55 Gap extending in the circumferential direction 58 Inner wall of the shield 60 Electrical connector 70 Electrical contact 75 Electric wire 80 Support plate 90 Connector neck 92 Void 94 Notch 100 Sensor 110 Electrical conductor / External conductor 112 Direction of current 114 Magnetic field 116 Magnetic flux density 120 Electrical conductor / Neutral conductor 122 Direction of current 124 Magnetic field 126 Magnetic flux density 130 Time axis 132 Oscillation of Magnetic Flux Density 134 Asymptote 136 Asymptote 140. Trends in false triggers 142 Profile of false trigger trends 150 Minimum measurable residual current 152 Profile of the minimum measurable residual current 160 Optimal Locations 165 Optimal range

Claims

1. A sensor (100) for determining residual current in a dual-current-sensitive manner, - The sensor (100) comprises a magnetic field-sensitive element (10), a first main winding (30), a test winding, and a shielding body (50). - The magnetic field-sensitive element (10) has a through-aperture for the magnetic field-sensitive element, and the through-aperture for the magnetic field-sensitive element (10) is formed as an oval whose cross-section has two axes of symmetry. - The first main winding (30), each having multiple windings, and the test winding surround the magnetic field-sensitive element (10). - The shielding body (50) has a housing space configured to accommodate the magnetic field-sensitive element (10), the first main winding (30), and the test winding, - The containment space of the shielding body (50) is defined radially by the outer wall of the shielding body and the inner wall of the shielding body (58), - The inner wall (58) of the shielding body defines the opening through the shielding body (50), and the opening through the shielding body (50) is formed as an oval having two axes of symmetry. - The shielding body (50) has a gap (55) that extends in the circumferential direction in the region of the inner wall (58) of the shielding body, - The sensor (100) is configured to be positioned around at least two electrical conductors (110, 120), - In a sensor in which the magnetic field-sensitive element (10) through-aperture has two inner widths along two axes of symmetry having different extensions, The inner width along the axis of symmetry having the larger extension is in the range of 25.2 to 32 mm. The sensor (100) is characterized in that the magnetic field-sensitive element has a coercivity of 30 mA / cm or less.

2. The sensor (100) according to claim 1, characterized in that the magnetic field-sensitive element (10) is covered with an insulator (20), and the insulator (20) is disposed between the magnetic field-sensitive element (10) and the first main winding (30), and between the magnetic field-sensitive element (10) and the test winding.

3. The sensor (100) according to claim 1 or claim 2, wherein the sensor (100) has a second main winding (30), and the second main winding (30) surrounds the magnetic field sensitive element (10) and / or insulator (20) in a plurality of turns.

4. The sensor (100) according to any one of claims 1 to 3, characterized in that the sensor (100) has a spacer ring (40), and the spacer ring (40) is disposed between the inner wall of the shielding and the first main winding (30).

5. The sensor (100) according to any one of claims 1 to 4, characterized in that the shielding body (50) has a coating, particularly an electrical insulating coating.

6. The sensor (100) according to any one of claims 1 to 5, characterized in that the shielding body (50) has a material thickness in the range of 0.25 mm to 0.45 mm.

7. The sensor (100) according to any one of claims 1 to 6, characterized in that the circumferentially extending gap (55) has a gap width in the range of 0.1 mm to 2.0 mm.

8. The sensor (100) has an electrical connector (60), and the electrical connector (60) has a support plate (80), a connector neck (90), and a plurality of electrical contacts (70). - The electrical connector (60) has at least two electrical contacts (70) for each winding, - The electrical contact (70) is located radially on the outside of the outer wall of the shielding body, - The support plate (80) is positioned between the outer wall of the shielding body and the first main winding (30), - The connector neck (90) extends through the opening in the outer wall of the shielding body and connects the support plate (80) and the electrical contact (70) to each other. - The support plate (80) and the connector neck (90) each have corresponding cavities (92), and the cavities (92) are configured to receive the two electric wires (75) that are operationally coupled to each winding from the housing space, and to pass them from the housing space through the opening in the outer wall of the shielding body to the electrical contacts (70), - The sensor (100) according to any one of claims 1 to 7, characterized in that the cavity (92) has a notch (94) in a direction parallel to the outer wall of the shielding body, and the electric wire (75) can be installed in the central region of the cavity (92) by passing through the notch.

9. A protective circuit breaker for shutting off an electrical circuit when the residual current exceeds a limit value in an electrical circuit, having a sensor (100) according to any one of claims 1 to 8, comprising an operating circuit, an electronic data processing and evaluation unit, and a switching device, - The sensor (100) is arranged around at least two electrical conductors (110, 120) that form the electrical circuit. - The switching device is set to interrupt the electrical circuit, - The operating circuit is set to operate the sensor (100), - The electronic data processing and evaluation unit is configured to evaluate the sensor signal of the sensor (100), - The electronic data processing and evaluation unit is configured to drive the switching device with a current intensity greater than a limit value, particularly an adjustable limit value, so that the switching device interrupts the electrical circuit when a residual current is detected, especially when a residual current is detected in a bicurrent-sensitive manner.

10. A charging cable for charging an electric vehicle, wherein the charging cable has a sensor (100) according to any one of claims 1 to 8 or a protective circuit breaker according to claim 9.

11. A charging station for charging an electric vehicle, wherein the charging station has a sensor (100) according to any one of claims 1 to 8 or a protective circuit breaker according to claim 9.

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