Compact Rogowski Current Sensor PCB Assembly
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Solution Overview
Problem
Existing current sensors in industrial installations face challenges in compactness, accuracy, and susceptibility to outside perturbations, particularly in three-phase systems where close proximity between current lines and sensors can lead to measurement interference.
Innovation Solution
A compact current-measuring device with Rogowski-type sensors positioned in a quincunx configuration on parallel printed circuit assemblies, ensuring precise alignment and insulation, and connected in series to minimize spatial requirements and interference, using pre-impregnated resin bonding and solder mask for insulation and precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current sensors are installed around each current line in a three-phase installation, then current measurement is achieved, but the device size and spatial requirements increase
Solution Approach 1:
The patent combines multiple current sensors (first, second, and third current sensors for three-phase measurement) into a single integrated sensor assembly mounted on one printed circuit board. This merging approach maintains the capability to measure all three phases while reducing the overall spatial footprint compared to installing separate sensor units for each phase.
Solution Approach 2:
The patent transitions from a distributed spatial arrangement of sensors to a planar two-dimensional arrangement on a printed circuit board. By laying out the sensor windings in specific patterns (with rectilinear portions positioned at different locations) on the PCB plane, the three-phase measurement capability is achieved within a compact two-dimensional footprint rather than requiring three-dimensional separation of sensor units.
2Volume of moving object
If current sensors are positioned in close proximity to current lines, then compact installation is achieved, but measurement accuracy deteriorates due to electromagnetic perturbations from nearby current lines
Solution Approach 1:
The patent implements local quality by positioning the rectilinear winding portions of the current sensors in specific locations on the printed circuit board. The first rectilinear portion is positioned between the first and second apertures, the second rectilinear portion faces the first, and the third rectilinear portion is positioned between the second and fourth apertures. This strategic local positioning optimizes each sensor's measurement capability while minimizing interference from adjacent current lines.
Solution Approach 2:
The patent converts the potentially harmful electromagnetic interference from nearby current lines into a beneficial measurement mechanism. By positioning the rectilinear winding portions of the sensors to face each other and arranging them in a specific pattern, the sensor assembly measures the differential magnetic fields, effectively using the presence of multiple current lines to enhance measurement accuracy through differential measurement rather than suffering from interference.
3Volume of moving object
If multiple current sensors are integrated on a single printed circuit board, then device compactness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent makes the printed circuit board multi-functional by integrating multiple current sensor windings, aperture structures, and mounting features into a single universal component. The PCB serves simultaneously as the structural support, the electrical connection medium, the mechanical mounting platform for the sensor assemblies, and the pathway for current lines. This universality reduces the total component count and simplifies manufacturing compared to using separate components for each function.
Solution Approach 2:
The patent segments the current sensor assembly into distinct functional regions on the printed circuit board: aperture regions for current line passage, winding regions for magnetic field sensing, and connection regions for electrical output. This segmentation allows each region to be optimized independently while maintaining overall compactness, and facilitates manufacturing by allowing modular fabrication of different PCB sections that can be assembled together.
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 achieves a compact, accurate, and robust current measurement system with minimal interference from external perturbations, suitable for high-density industrial installations, ensuring consistent signal delivery across sensors and facilitating mass production.
Implementation Method 1
a first current sensor positioned around the first aperture so as to measure the current flowing in the first current line
Data Source
AI summary
A compact current-measuring device including a first printed circuit assembly including a first current sensor positioned around a first aperture and a second aperture, and a second printed circuit assembly including a second current sensor positioned around a third aperture. The second sensor includes a second rectilinear winding portion positioned facing a first rectilinear winding portion of the first current sensor. The second aperture is positioned facing the third aperture. A unit for measuring the electric current flowing in current lines of an electrical installation, and a method for manufacturing a current-measuring device.