Current Sensor with Dielectric Between Coil and Conductor
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Solution Overview
Problem
Existing current sensor devices in utility meters, such as transformer and Rogowski coils, are either bulky and expensive or provide limited accuracy at low and high current conditions, requiring multiple calibration processes that increase manufacturing time and cost.
Innovation Solution
A sensor device featuring a non-magnetic substrate with a coil and dielectric material positioned between the coil and conductor, reducing capacitance and enhancing accuracy across a range of currents and voltages, thereby simplifying calibration and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a transformer sensor device is used, then the sensor device can sense current, but the device becomes bulky and expensive
Solution Approach 1:
The patent changes the physical parameters of the sensor device by using a Rogowski coil configuration instead of a traditional transformer core, and introduces a dielectric material with specific properties (dielectric constant between 2.0 and 10.0) to optimize the sensing characteristics. This allows accurate current sensing with a more compact form factor.
Solution Approach 2:
The patent employs a composite structure combining a coil with a dielectric material positioned between the coil and conductor. This composite arrangement creates a capacitor-like structure that enhances the sensing accuracy while maintaining a compact size, resolving the contradiction between measurement precision and device volume.
2Volume of moving object
If a Rogowski coil is used, then the device size is reduced, but the accuracy is limited during low current and high current conditions
Solution Approach 1:
The dielectric material acts as an intermediary element between the coil and the conductor, creating a controlled capacitive coupling that enhances the Rogowski coil's accuracy across the full current range. This intermediary structure allows the compact Rogowski coil to achieve transformer-level accuracy without the bulk.
Solution Approach 2:
By introducing a dielectric material with a specific dielectric constant range (2.0-10.0), the patent modifies the electrical parameters of the sensing system to optimize accuracy at both low and high current conditions while maintaining the compact Rogowski coil structure.
3Measurement precision
If multiple calibration processes are performed, then the accuracy of Rogowski coils is improved, but the manufacturing time and costs increase
Solution Approach 1:
The dielectric material structure is designed to provide inherent calibration stability, allowing the sensor device to maintain accuracy across varying current and voltage conditions without requiring multiple manual calibration processes. This self-calibrating design significantly reduces manufacturing time and costs.
Solution Approach 2:
The specific dielectric material configuration creates a sensing system with stable electrical characteristics that minimize drift and variability, reducing the need for repeated calibration processes during manufacturing while maintaining high accuracy across the operating range.
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
The sensor device achieves improved accuracy and reduced calibration requirements, enabling consistent current sensing at various voltages and currents with fewer calibration processes, resulting in cost and time savings during manufacturing.
Implementation Method 1
a dielectric material positioned adjacent to the coil and at least partially within the aperture such that the dielectric material is between the coil and a conductor positioned in the aperture
Implementation Method 2
a coil comprising a plurality of turns wound about the substrate, the coil defining an aperture structured to receive a conductor therein
Data Source
AI summary
Sensor devices and related methods disclosed. One example sensor device includes a non-magnetic substrate, a coil comprising a plurality of turns wound about the substrate, the coil defining an aperture structured to receive a conductor therein; and a dielectric material positioned adjacent to the coil and at least partially within the aperture such that the dielectric material is between the coil and a conductor positioned in the aperture.