Integrated Coil Carrier for Current Sensor Assembly
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Solution Overview
Problem
The manufacturing of current sensors with compensation windings is complex and costly due to the manual assembly of coil carriers and sensor strips, making the process error-prone and inefficient.
Innovation Solution
A coil carrier design with a central section of reduced cross-sectional area integrates the sensor strip and compensation winding, allowing for automated assembly and reduced complexity, where the sensor coil is wound around the coil carrier to enclose the strip, and a film covers the central region to facilitate uniform winding and shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate coil carrier and sensor strip carrier are used and manually assembled, then manufacturing flexibility is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the coil carrier and sensor strip carrier into a single integrated coil carrier structure. The sensor strip is mounted directly on the coil carrier in a recess, eliminating the need for a separate sensor strip carrier and reducing the number of assembly steps from manual joining of two components to a single integrated structure.
Solution Approach 2:
The coil carrier serves multiple functions: it acts as both the structural support for the compensation coil and the mounting base for the sensor strip. This multi-functional design eliminates the need for separate specialized carriers for each component, simplifying the overall device structure.
2Productivity
If manual assembly of coil carrier and sensor strip is performed, then assembly precision can be controlled, but productivity decreases and errors increase
Solution Approach 1:
The sensor strip is pre-mounted in a recess on the coil carrier during the carrier manufacturing process itself, rather than being attached separately during assembly. This preliminary integration ensures precise positioning is built into the structure from the outset, enabling subsequent automated winding operations without compromising precision.
Solution Approach 2:
The coil carrier structure itself provides the positioning and mounting features for the sensor strip through its integrated design with recesses and mounting surfaces. The structure serves its own assembly needs, eliminating the requirement for complex external fixtures or manual alignment procedures.
3Extent of automation
If sensor strip is applied to adhesive film and installed semi-automated, then automation is partially achieved, but manufacturing complexity and cost remain high
Solution Approach 1:
The patent eliminates the adhesive film intermediary by integrating the sensor strip mounting directly into the coil carrier structure. The sensor strip is mounted in a recess on the carrier itself, removing the need for separate adhesive film application and semi-automated installation processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies and cost-reduces the manufacturing of current sensors by integrating components, reducing errors and enabling automated production, while also providing effective shielding against external magnetic fields.
Implementation Method 1
a sensor coil (22) which is wound around the coil carrier (1) in the central region (11) so that it encloses the sensor strip (21)
Implementation Method 2
a magnetic field probe having a ferromagnetic sensor strip (21)
Implementation Method 3
the sensor electronics provide a compensation current (secondary current) that flows through a compensation coil which causes a flux in the opposite direction in the soft magnetic core
Implementation Method 4
The superposition (sum) of the magnetic flux components caused by the primary current and the compensation current is regulated to zero (by means of a closed control loop). This is done by means of a magnetic field probe.
Data Source
AI summary
A device which can be used for current measurement is described hereinafter. According to one exemplary embodiment, the device comprises the following: a coil carrier extending along a longitudinal axis having a base body which in a central region has a section having reduced cross-sectional area, which is smaller than the cross-sectional area outside the central region, and a magnetic field probe having a ferromagnetic sensor strip, which is fastened to the coil carrier in the section having reduced cross-sectional area, and having a sensor coil which is wound around the coil carrier in the central region so that it encloses the sensor strip. The device also comprises a film which at least partially covers the section having reduced cross-sectional area. A secondary winding is wound around the coil carrier, wherein the secondary winding is wound around the film in the section having reduced cross-sectional area.