Hall Effect Current Sensor Solid Dielectric Insulation
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Solution Overview
Problem
Conventional Hall Effect current sensors are not sufficiently insulated for medium-voltage applications, leading to bulky and costly solutions with increased complexity, volume, and assembly time due to the need for additional components like shielded cables and metal barriers, which are not efficiently handled by existing low-voltage sensors.
Innovation Solution
A Hall Effect current sensor with a closed core made of magnetic material and encapsulated in a molded case of solid dielectric material, designed to operate within a wide range of medium-voltage frequencies, eliminating the need for external air spacings and bulky components by using a solid dielectric material with higher breakdown strength, and integrating a grounded metal barrier for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional low-voltage Hall Effect current sensors are used in medium-voltage applications, then the sensor can measure current, but the insulation is insufficient requiring additional bulky components
Solution Approach 1:
The patent changes the insulation parameter by transitioning from air spacing to solid dielectric material. The molded case encapsulates the magnetic core and conductor, providing sufficient insulation for medium-voltage applications (1,000 to 69,000 volts) without requiring large external air spacings. This parameter change resolves the contradiction by maintaining reliability while reducing volume.
Solution Approach 2:
The patent uses composite materials by combining magnetic material for the closed core with solid dielectric material for the molded case. This composite structure provides both the magnetic properties needed for current sensing and the insulation properties needed for medium-voltage applications, eliminating the need for separate insulation components and reducing overall assembly volume.
2Reliability
If large air spacings are used to achieve higher insulation levels, then insulation capability is improved, but the sensor becomes bulky and costly
Solution Approach 1:
The patent changes the insulation parameter from air spacing to solid dielectric material with higher breakdown strength. This allows sufficient insulation for medium-voltage applications without requiring large spacings, thereby reducing structural complexity and eliminating the need for bulky components while maintaining reliability.
3Reliability
If shielded medium-voltage cables are used with low-voltage sensors, then insulation is improved, but assembly complexity and time increase due to additional components
Solution Approach 1:
The patent merges the insulation function directly into the sensor assembly by encapsulating the magnetic core and conductor in a molded case of solid dielectric material. This integration eliminates the need for separate shielded cables and external insulation components, reducing assembly complexity and time while maintaining sufficient insulation for medium-voltage applications.
Solution Approach 2:
The molded case serves multiple functions: it provides structural support for the magnetic core and conductor, provides electrical insulation for medium-voltage applications, and eliminates the need for separate shielded cables. This multi-functionality resolves the contradiction by improving reliability while reducing assembly time.
4Adaptability or versatility
If conventional low-voltage sensors are used in medium-voltage applications, then current measurement is possible, but additional safety components are required
Solution Approach 1:
The patent changes the insulation parameter by using solid dielectric material with higher breakdown strength, enabling the sensor to operate directly in medium-voltage applications without requiring additional safety barriers or grounded metal enclosures. This parameter change allows the sensor to handle voltages from 1,000 to 69,000 volts directly, improving adaptability while reducing complexity.
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 solution reduces complexity, volume, and assembly time while maintaining effective insulation and safety, allowing for direct connection of medium-voltage currents without the need for additional components, thus reducing costs and space requirements.
Implementation Method 1
A Hall Effect element is mounted in the gap and produces a signal which is a measure of the current flowing in the conductor.
Implementation Method 2
a molded case of solid dielectric material configured to encapsulate the closed core and the at least one conductor, wherein the gap, the input terminal and the output terminal are not encapsulated by the molded case. The molded case is dimensioned such that internal and external spacings defined by the molded case are suitable for continuous operation with an AC voltage between the range of 1,000 volts and 69,000 volts
Data Source
AI summary
A current sensor for measuring medium-voltage currents. The current sensor includes an input terminal configured to receive a current, an output terminal configured to transmit the current, a closed core made from a magnetic material and comprising a gap, at least one conductor operably connected to the input terminal and the output terminal and passing through the closed core, the at least one conductor sized to carry the current, and a molded case of solid dielectric material configured to encapsulate the closed core and the at least one conductor, wherein the gap and the terminals are not encapsulated by the molded case. The molded case is dimensioned such that internal and external spacings defined by the molded case are suitable for continuous operation with a medium voltage current as applied to the terminals and the at least one conductor while the core is at ground potential.