Sensor-Integrated Insulator With Centered Annular Measurement Frame
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Solution Overview
Problem
Existing insulators face challenges in ensuring precise sensor positioning and reliable measurements due to their bulkiness and the need for correct sensor placement, which affects the accuracy of voltage and current detection.
Innovation Solution
An insulator design featuring a frame that supports annular sensors, with anchoring elements for precise centering during the moulding process, ensuring accurate sensor placement and integration within a compact, cost-effective structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are integrated inside the insulating body, then voltage and current detection functions are provided, but sensor positioning precision deteriorates leading to unreliable measurements
Solution Approach 1:
A frame structure is introduced as an intermediary component between the sensor and the insulating body. The frame includes a support element with anchoring elements that couple to the mould during injection moulding, and a positioning element that centers the sensor on the conductor axis. This intermediary structure ensures precise sensor positioning while integrating the sensor into the insulating body during the moulding process.
2Volume of moving object
If the insulator structure is made compact to reduce bulk, then space is optimized, but sensor positioning becomes more difficult leading to detection unreliability
Solution Approach 1:
The frame structure utilizes the radial dimension by extending from the conductor surface outward, with the support element having a radial thickness that positions the sensor at an optimal distance from the conductor. The anchoring elements extend axially to couple with the mould, while the positioning element ensures concentric positioning. This multi-dimensional approach enables compact insulator design while maintaining precise sensor positioning.
3Ease of manufacture
If traditional sensor integration methods are used, then manufacturing is simpler, but sensor centering on the conductor axis cannot be ensured leading to poor detection accuracy
Solution Approach 1:
The frame is pre-assembled with the sensor before the injection moulding process. The support element is coupled to the sensor, and the positioning element is configured to center the sensor on the conductor axis during moulding. The anchoring elements are prepared to couple with the mould. This preliminary preparation ensures that when the moulding process occurs, the sensor is already positioned correctly and will remain centered, achieving both manufacturing efficiency and measurement precision.
Data Source
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Figure 5
AI summary
An insulator comprises a primary conductor (2) extending along a longitudinal axis (A); and an insulating body (4), which surrounds, at least in part, the primary conductor (2) and comprises: • at least one annular sensor (11; 11a, 11b, 11c), selected from the group comprising a current sensor (11a), a voltage measurement sensor (11b), a voltage detector (11c); and • a frame (12; 112) configured to support the at least one annular sensor (11; 11a, 11b, 11c) such that the at least one annular sensor (11; 11a, 11b, 11c) is centred on the longitudinal axis (A).