Mixed Current Sensor Linking Cassette Assembly
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Solution Overview
Problem
The industrialization of Rogowski-type current measurement devices is hindered by difficulties in fitting coils onto torus-shaped supports due to their geometry, leading to challenges in securing and positioning the components.
Innovation Solution
A mixed current sensor design featuring a linking cassette with clip-fastening means and centring pins that securely position and fix the Rogowski coil and electronic acquisition means within a case, utilizing a system of mortise and tenon type clip-fastening and automated soldering processes like laser tin brazing for reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a torus-shaped support is used for the Rogowski coil, then the measurement range is improved without magnetic core saturation, but the fitting and assembly process becomes difficult to industrialize
Solution Approach 1:
The device is divided into separate modular components: the Rogowski coil assembly with insulating shell, the linking cassette, and the base housing. This segmentation allows each component to be manufactured and assembled independently, simplifying the industrialization process while maintaining the torus-shaped coil geometry for accurate measurement.
Solution Approach 2:
A linking cassette is introduced as an intermediary component that connects the Rogowski coil assembly to the base housing. This mediator facilitates the assembly process by providing standardized connection interfaces, making the overall device easier to industrialize without compromising the measurement capabilities of the torus-shaped coil.
2Productivity
If a closed torus geometry is used for the coil support, then measurement efficiency is improved, but fitting difficulties arise
Solution Approach 1:
The closed torus coil is segmented into a coil assembly that fits within an insulating shell, which is then connected to the base housing via a linking cassette. This segmentation maintains the efficient closed-loop geometry for measurement while enabling practical fitting and assembly operations.
Solution Approach 2:
The Rogowski coil is pre-assembled within the insulating shell before final installation into the base housing through the linking cassette. This preliminary assembly simplifies the fitting process by reducing the number of steps required during final installation, thereby improving ease of operation without compromising measurement efficiency.
3Ease of manufacture
If traditional assembly methods are used for the Rogowski coil, then manufacturing simplicity is maintained, but positioning precision and security are insufficient
Solution Approach 1:
The linking cassette serves as a precision intermediary component that provides accurate positioning features and secure connection mechanisms between the Rogowski coil assembly and the base housing. This mediator enables precise positioning without complicating the overall manufacturing process, as the cassette can be manufactured as a standardized component.
Solution Approach 2:
Traditional mechanical assembly methods are supplemented or replaced with automated soldering processes for electrical connections and secure mechanical fastening systems for positioning. This substitution maintains manufacturing simplicity through automation while significantly improving positioning precision and assembly security.
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
This design simplifies the industrialization of current measurement devices by ensuring reproducible positioning and secure attachment, facilitating efficient assembly and enhancing the measurement range without magnetic core saturation, thus overcoming the limitations of existing solutions.
Implementation Method 1
a magnetic current sensor having a coil wound around a magnetic circuit
Implementation Method 2
A conducting wire is wound onto the support to form a secondary winding. The assembly forms a transformer where said current conductor or line constitutes a primary winding and said secondary winding provides a measurement signal.
Data Source
AI summary
The invention relates to a mixed current sensor comprising in a case:a magnetic current sensor;a current measuring device comprising a Rogowski coil arranged in such a way that a primary circuit of the magnetic sensor corresponds to the primary circuit of said current measuring device,electronic means for performing acquisition and measurement of the electric current.Said sensor comprises a linking cassette comprisingfirst fixing means arranged to position and secure said cassette by clip-fastening onto the measuring device;second fixing means arranged to position and secure said cassette and the measuring device by clip-fastening onto the case.