Excitation Core Overlapping Ends Design for Current Sensor
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Solution Overview
Problem
Conventional excitation cores made of thin strip-shaped magnetic substances lose mechanical strength and reproducibility when used in divided clamp-type contactless current sensors, leading to contact failures and unreliable current measurement due to insufficient contact areas and mechanical instability during opening and closing operations.
Innovation Solution
An excitation core design featuring a first and second strip-shaped magnetic substance with overlapping ends, reinforced by non-magnetic U-shaped members forming an annular structure, ensuring sufficient contact areas and mechanical strength, allowing the use of thin strip-shaped magnetic substances in divided clamp-type contactless current sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin strip-shaped magnetic substances are wound and stacked to form an excitation core, then cost is reduced and performance is improved, but mechanical strength is lost and contact reliability deteriorates during opening and closing operations
Solution Approach 1:
The invention uses a composite structure combining thin strip-shaped magnetic substances with a flexible support body. The magnetic substances are arranged in a ladder-like pattern and fixed to the flexible support body, creating a composite structure that leverages the magnetic properties of the thin strips while relying on the flexible support body for mechanical strength and flexibility. This resolves the contradiction by allowing cost-effective thin magnetic strips to be used without sacrificing the mechanical integrity needed for repeated opening and closing operations.
2Device complexity
If thin strip-shaped magnetic substances are used in divided clamp-type sensors, then device complexity is reduced, but contact area becomes insufficient leading to contact failures
Solution Approach 1:
The invention transitions from a simple linear arrangement of magnetic strips to a three-dimensional ladder-like structure. The magnetic substances are arranged in multiple rungs along the flexible support body, creating a spatial distribution that increases the effective contact area between the excitation core and the clamp. This dimensional transformation maintains structural simplicity while significantly improving contact reliability through increased contact points and area.
3Ease of operation
If the excitation core is divided into two for clamp-type design, then ease of operation is improved, but mechanical stability deteriorates leading to reproducibility issues
Solution Approach 1:
The invention incorporates a flexible support body that can dynamically bend and deform during opening and closing operations. This flexible backbone allows the divided excitation core to adapt to mechanical stress and maintain proper alignment between the two halves. The dynamic flexibility of the support body compensates for the instability introduced by the divided structure, ensuring consistent contact and reproducible measurements throughout the operational cycle.
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 maintains mechanical strength and reproducibility of current measurements by ensuring consistent contact areas between the magnetic substances, enabling reliable operation of divided clamp-type contactless current sensors without contact failures.
Implementation Method 1
an excitation core (3A) including a first strip-shaped magnetic substance (3A2) and a second strip-shaped magnetic substance (3A3), and both ends of the first strip-shaped magnetic substance (3A2) and both ends of the second strip-shaped magnetic substance (3A3) are overlapped with one another and are in contact with one another in a thickness direction
Data Source
AI summary
An excitation core includes a first strip-shaped magnetic substance and a second strip-shaped magnetic substance. The first strip-shaped magnetic substance has both ends mutually overlapped with and mutually in contact with both ends of the second strip-shaped magnetic substance in a thickness direction. A sensor head includes this excitation core and a magnetism collecting body. This magnetism collecting body includes strip-shaped first magnetism collector and second magnetism collector. Both ends of the first magnetism collector and both ends of the second magnetism collector are in contact with one another to form the annular magnetism collecting body. This magnetism collecting body is disposed at an inside or an outside of the reinforcing body.