Planar Coil Current Sensor with Soft Magnetic Core
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Solution Overview
Problem
Current current sensors, particularly Rogowski coils, face challenges in being retrofitted around conductors and achieving optimal sensitivity and size compatibility in densely packed environments like electricity substations, with existing solutions often being too large or complex to accommodate.
Innovation Solution
A sensor design featuring plural coils printed on planar substrates with soft magnetic components, arranged to create an equivalent infinite solenoid effect, allowing for compact and sensitive current measurement with the option for retrofittable configurations using U-shaped or rectangular coil stacks and magnetic bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional Rogowski coils are used, then sensitivity to magnetic fields is improved, but device size and complexity increase making retrofitting difficult
Solution Approach 1:
The sensor is divided into a first component containing multiple coils and a second component containing soft magnetic material. This segmentation allows the coils to be arranged in a simplified configuration while maintaining sensitivity, and enables retrofittable designs where the components can be assembled around existing conductors without requiring complex pre-formed toroidal structures.
2Volume of moving object
If sensor size is reduced for compact environments, then adaptability to densely packed substations is improved, but manufacturing precision requirements increase
Solution Approach 1:
By segmenting the sensor into modular first and second components, the design achieves compactness while allowing tolerance accumulation between assembled parts rather than requiring high precision in a single monolithic structure. The multiple coils can be arranged on separate substrates that are stacked or mounted together, reducing overall footprint while maintaining manufacturing feasibility.
Solution Approach 2:
The sensor utilizes three-dimensional stacking of coil substrates with soft magnetic material components to achieve compact volume. Coils are arranged in multiple layers or orientations, transforming a potentially large planar configuration into a compact volumetric structure that fits densely packed environments while maintaining adequate spacing for manufacturing tolerances.
3Ease of manufacture
If irregular coil spacing is used to simplify manufacture, then ease of manufacture is improved, but measurement precision deteriorates
Solution Approach 1:
The sensor divides the coil system into multiple separate coils on different substrates within the first component. This allows each coil to be manufactured independently with standard PCB techniques, achieving ease of manufacture. The segmented structure enables flexible arrangement where coils can be positioned at irregular intervals while still providing adequate spatial distribution for acceptable measurement uniformity across the sensing zone.
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 provides high sensitivity and compactness, enabling accurate current measurement in densely packed environments while allowing for retrofittable solutions, maintaining sensitivity and accuracy with reduced size and complexity.
Implementation Method 1
A current sensor can be used for measurement of current in a conductor... sensitive to magnetic fields generated by the encircled conductor
Implementation Method 2
a second component comprising soft magnetic material... Magnetic circuits with a sensing coil in an air gap between two soft magnetic components
Data Source
AI summary
A current sensor comprises a first component comprising plural coils. Each coil comprises one or more turns printed on at least one planar surface of a respective substrate, and the planes of the coils are parallel to one another and are perpendicular to a longitudinal axis of the first component. A second component comprises soft magnetic material and has first and second planar faces that are at opposite ends of the first component and are arranged perpendicularly to and are intersected by the longitudinal axis of the first component.