Current Transformer Integrated Connector Socket
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current transformers face labor-intensive installation processes and high risks of wiring errors, as well as safety hazards due to exposed terminals and potential high voltages when the secondary circuit is open-circuit.
Innovation Solution
A current transformer design featuring a housing with magnetic cores, secondary windings, shunt circuitry, and a connector socket that eliminates exposed terminals and ensures the secondary circuit remains loaded, reducing installation labor and eliminating wiring errors by allowing a single cable connection, while also providing protection against electrocution through shunt circuitry and protection circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional terminal connections are used for secondary windings, then electrical connection can be established, but installation labor increases and wiring errors become more likely
Solution Approach 1:
The patent combines multiple secondary winding terminals into a single integrated connector assembly. The connector integrates multiple electrical contacts and insulation structures into one unified component that connects to the transformer housing as a single unit, eliminating the need for separate terminal connections and reducing installation complexity.
Solution Approach 2:
The patent introduces a connector as an intermediary component between the secondary windings and the external circuit. This connector serves as a mediator that simplifies the connection interface, providing both electrical connectivity and mechanical mounting in a single component that reduces the number of discrete connection steps required.
2Ease of operation
If exposed terminals are provided for secondary connections, then electrical connection is enabled, but safety hazards increase due to potential electrocution
Solution Approach 1:
The patent implements a nested structure where the electrical terminals are housed within an insulated connector body that is itself mounted within the transformer housing. The connector contains the exposed conductive elements, and the housing provides an additional layer of enclosure, creating multiple nested protective barriers that eliminate direct exposure to dangerous voltages.
Solution Approach 2:
The patent uses insulating materials and protective enclosures that form flexible barriers between the user and exposed electrical terminals. The connector housing and transformer case act as insulating shells that prevent contact with high-voltage elements while still allowing electrical functionality.
3Adaptability or versatility
If secondary circuit is left open-circuit, then connection flexibility is maintained, but high voltage induction occurs causing arcing and safety risks
Solution Approach 1:
The patent incorporates protective measures into the connector design before any open-circuit condition can develop. The connector includes built-in protective elements such as protective resistors or voltage-clamping components that are预先 installed in the circuit path, so that if an open-circuit condition occurs, these pre-installed protective elements automatically limit the voltage and prevent dangerous high-voltage induction.
4Reliability
If multiple discrete terminals are used for secondary windings, then electrical connection is established, but installation time and labor increase
Solution Approach 1:
The patent merges multiple discrete terminal connections into a single integrated connector assembly. This connector contains all necessary electrical contacts for the secondary windings and mounts to the transformer housing as one unified component, reducing the number of separate connection operations required while maintaining reliable electrical connectivity for all secondary circuits.
Solution Approach 2:
The patent segments the connection function into two distinct parts: the connector assembly that contains all electrical terminals and mounting features, and the transformer housing that provides structural support and electrical isolation. This segmentation allows the connector to be pre-assembled and tested independently, then quickly installed as a single unit, improving installation efficiency without compromising connection reliability.
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 design significantly reduces labor costs and eliminates wiring errors, ensures safety by preventing electrocution, and offers flexibility in cable length and configuration, while maintaining effective electromagnetic coupling and accurate current measurement.
Implementation Method 1
an electric current passing through the primary cable or busbar within one of the apertures 12a, 12b, 12c will produce a magnetic field in the respective magnetic core 18a, 18b, 18c which in turn induces a much smaller current in the respective secondary winding 20a, 20b, 20c
Implementation Method 2
one or more magnetic cores enclosed within the housing and being positioned proximate to respective ones of the apertures so that a magnetic field is produced in a magnetic core when a primary current flows through a primary cable or busbar received through the respective aperture
Data Source
AI summary
A current transformer is described which comprises a housing having one or more apertures, each for receiving a primary cable or busbar, one or more magnetic cores enclosed within the housing and being positioned proximate to respective ones of the apertures so that a magnetic field is produced in a magnetic core when a primary current flows through a primary cable or busbar received through the respective aperture, and one or more secondary windings enclosed within the housing, each secondary winding being wrapped around at least a portion of a respective magnetic core so that a secondary current is induced in a secondary winding when a magnetic field is produced in the respective magnetic core. Shunt circuitry is enclosed within the housing and is connected across the secondary windings to generate a respective voltage signal for each secondary winding. A connector socket is integrally mounted to the housing for outputting the voltage signals. In this way, the labor costs incurred during installation of the current transformer can be reduced, a risk of wiring errors can be avoided, and a risk of electrocution from secondary terminals being left open-circuit is removed.