High Voltage Sensor Isolating Transformer Design
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Solution Overview
Problem
Existing high voltage sensors face challenges in simplifying construction, reducing manufacturing costs, ensuring consistent isolation properties, and maintaining high performance and accuracy over time while avoiding electrical creep and breakdown, especially in transmitting signals and power between high and low voltage environments.
Innovation Solution
A high voltage sensor design featuring a dual transformer core isolating transformer with coils on circuit boards, an intermediate coil for reduced stray capacitance, and a micro-controller for signal processing and power control, allowing for adaptable configuration and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional isolating transformer with U-shaped terminals and conductive circuit traces is used, then isolation properties are maintained, but construction complexity increases and manufacturing cost rises
Solution Approach 1:
The patent combines the transformer core, coils, and circuit board into an integrated structure where the circuit board serves dual purposes as both the mounting substrate and the structural support for the transformer assembly. The first and second circuit boards are merged with the respective transformer cores to form unified isolating transformer units, reducing the number of separate components and simplifying construction.
Solution Approach 2:
The circuit boards are designed to serve multiple functions: they provide electrical connections through conductive traces, mechanically support the transformer cores and coils, provide structural rigidity to the isolating transformer assembly, and serve as mounting surfaces for other sensor components. This multi-functionality reduces the need for additional structural components.
2Power
If traditional wire-wound transformer coils are used, then power transmission is achieved, but capacitive coupling with transformer core increases causing measurement error
Solution Approach 1:
The patent replaces the traditional wire-wound coil structure with planar coils formed by conductive traces on the circuit board. This substitution changes the physical configuration from three-dimensional wire winding to two-dimensional planar geometry, reducing the capacitive coupling area with the transformer core while maintaining the electromagnetic transformation function.
Solution Approach 2:
The transformer coils are transitioned from a three-dimensional wire-wound configuration to a two-dimensional planar configuration on the circuit board. This dimensional change reduces the proximity and coupling area between the coils and the transformer core, thereby minimizing parasitic capacitance and improving measurement accuracy.
3Ease of operation
If multiple separate parts are used in isolating transformer, then flexibility in assembly is achieved, but number of faulty parts increases and reliability decreases
Solution Approach 1:
The patent merges the circuit board and transformer core into integrated assemblies where the circuit board serves as both the electrical connection medium and the structural support. This integration reduces the number of separate parts that need to be assembled and connected, thereby reducing potential failure points and improving overall reliability.
4Reliability
If complex transformer construction is used, then isolation properties are ensured, but manufacturing cost increases
Solution Approach 1:
The integration of circuit boards with transformer cores and coils into unified assemblies reduces the number of separate manufacturing steps and component assembly operations. This consolidation simplifies the manufacturing process and reduces costs while maintaining the required isolation properties through the integrated design.
5Power
If traditional transformer design is used, then power transmission is achieved, but consistency of isolation properties varies
Solution Approach 1:
The integrated design where circuit boards are combined with transformer cores ensures consistent positioning and spacing, eliminating variations that occur with separate assembled components. This integration improves the consistency of isolation properties across manufactured units while maintaining effective power transmission.
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 achieves robust, reliable, and cost-effective measurement of electrical parameters with improved isolation and reduced defects, enabling accurate and consistent performance across varying operating ranges.
Implementation Method 1
at least one isolating transformer for transmission of electrical power supply and/or measurement signals from the low voltage side to the high voltage side or from the high voltage side to the low voltage side
Implementation Method 2
The isolating transformer further comprises an intermediate coil encircling at least one branch of each said at least two transformer cores
Data Source
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AI summary
Sensor for measuring electrical parameters in a high voltage environment comprising a high voltage side (4) for connection to high voltage conductors, a low voltage side (6) for connection to low voltage power supply and measurement signal control circuitry, a measurement signal circuit (16), and a power supply circuit (14), and at least one isolating transformer (18, 20) for transmission of electrical power supply and/or measurement signals between the low voltage side and the high voltage side. The isolating transformer comprises at least a first and a second transformer core (28), a transformer coil (33) on a circuit board around a branch (27) of the transformer core on the high voltage side and a transformer coil (32) on a circuit board around a branch (29) of the transformer core on the low voltage side, the isolating transformer further comprising an intermediate coil (36) encircling at least one branch of each said at least two transformer cores.