Detachable Conductor Sensor Assembly for Serviceable Current Sensing
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Solution Overview
Problem
Existing sensor assemblies for electric drive systems, such as those described in U.S. Patent Application Publication No. 20230042505, suffer from unreliable sensing performance due to bulkiness, electrical shorts, wire abrasion, and cable disconnection issues in wired connections, making them inaccessible for servicing or replacement.
Innovation Solution
A detachable sensor assembly for elongate conductors, comprising a circuit board with a sensor chip, a field component, and a housing with separable portions, securely attaches to the conductor using fasteners, allowing precise positioning and reducing external connections to enhance measurement accuracy and resilience to vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired connections are used to transmit sensor signals externally, then signal transmission is achieved, but the assembly becomes bulky and susceptible to electrical shorts, wire abrasion, and cable disconnection
Solution Approach 1:
The patent replaces wired mechanical connections with wireless communication technology. The sensor assembly includes a wireless transceiver that communicates with external devices via wireless signals (e.g., WiFi, Bluetooth, or other wireless protocols), eliminating the need for physical wire connections between the sensor assembly and external systems.
Solution Approach 2:
The patent extracts and removes the wiring system from the sensor assembly. By eliminating wires, connectors, and associated mounting hardware, the design reduces mechanical complexity and potential failure points while maintaining signal transmission functionality through wireless communication.
2Ease of manufacture
If the sensor assembly is assembled around the bus bar prior to connecting the bus bar to an electrical device, then the sensor can be installed, but the sensor assembly becomes inaccessible for servicing or replacement
Solution Approach 1:
The patent divides the sensor assembly into separable components: a sensor module that can be independently removed from the housing. The housing includes a removable cover or access panel that allows the sensor module to be accessed, replaced, or serviced without disconnecting the bus bar from the electrical device.
Solution Approach 2:
The patent incorporates dynamic access mechanisms such as removable covers, sliding panels, or magnetic attachments that allow the sensor assembly to be opened or accessed after installation. This enables maintenance personnel to service the sensor without disrupting the electrical connection of the bus bar.
3Device complexity
If the sensor assembly is made compact to reduce bulkiness, then wireless communication is enabled, but precise positioning and retention of components becomes more challenging
Solution Approach 1:
The patent employs a nested structure where the sensor module, circuit board, and field component are compactly arranged within the housing. The circuit board is positioned to accommodate both the sensor module and wireless transceiver in a space-efficient manner, with components nested or layered to minimize the overall assembly footprint while maintaining precise positioning.
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 assembly provides high-accuracy measurements with improved resilience to vibrations and temperature fluctuations, enabling efficient servicing and replacement without disconnecting the conductor, thus enhancing the reliability and uptime of electrical systems.
Implementation Method 1
The sensor measures a magnetic field resulting from a current traveling through the conductor
Data Source
AI summary
A sensor assembly for an elongate conductor may include a circuit board with a sensor chip, a field component configured to partially surround the elongate conductor transverse to a longitudinal axis of the elongate conductor, and a housing having a first housing portion to connect to a second housing portion by one or more fasteners. The housing may be configured to retain the elongate conductor, the circuit board, and the field component between the first housing portion and the second housing portion.