Segmented PCB Rogowski Coil for Flat-Mount Current Sensing
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Solution Overview
Problem
Traditional Rogowski coil PCBAs in circuit interrupters occupy significant vertical space due to their round or oval shape, with most of the surface area mounted perpendicularly to the primary conductor, making them cumbersome and inefficient in current measurement applications.
Innovation Solution
A modular design comprising multiple coupled PCBs, where three PCBs form a pre-assembled portion and a fourth PCB is connected via press-fit connectors to create a complete Rogowski coil, allowing the majority of the PCB surface area to be mounted in parallel to the primary conductor, significantly reducing space occupancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a traditional round or oval Rogowski coil PCBA is mounted perpendicularly to the primary conductor, then the coil can effectively capture the magnetic field, but it occupies significant vertical space making it cumbersome
Solution Approach 1:
The Rogowski coil PCBA is divided into multiple segmented sections that can be arranged in a flat configuration. Each segment contains portions of the coil windings, and when assembled together in a planar layout, they collectively form the complete Rogowski coil geometry, maintaining magnetic field capture while eliminating the need for perpendicular mounting
Solution Approach 2:
The design transitions from a three-dimensional perpendicular mounting arrangement to a two-dimensional flat-mount configuration. By redistributing the coil windings across multiple PCB segments in a planar arrangement, the magnetic field capture function is preserved while the vertical dimension is eliminated, allowing the coil to lie flat against the primary conductor
2Device complexity
If a single large PCB is used for the Rogowski coil, then the design is simple, but it occupies excessive space and is difficult to install in tight circuit interrupter configurations
Solution Approach 1:
The Rogowski coil PCBA is divided into multiple segmented sections that can be arranged in a flat configuration. Each segment contains portions of the coil windings, and when assembled together in a planar layout, they collectively form the complete Rogowski coil geometry, maintaining magnetic field capture while eliminating the need for perpendicular mounting
Solution Approach 2:
The segmented PCB design allows the coil sections to be nested or folded together in a compact arrangement. The multiple segments can be stacked or folded to fit within the limited space of circuit interrupters, while still forming the complete Rogowski coil structure when assembled
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 modular design of the Rogowski coil assembly effectively captures the magnetic field around the primary conductor, achieving the same sensitivity as traditional designs while occupying less space, thus improving the efficiency and compactness of current measurement in circuit interrupters.
Implementation Method 1
The AC current i(t) through the line conductor 4 produces a first voltage signal v(t) across the output terminals. This output voltage signal v(t) is proportional to the rate of change, di/dt, of the current through the line conductor 4.
Data Source
AI summary
An improved PCB Rogowski coil addresses the challenges presented by space constraints within circuit interrupters. The disclosed coil comprises a plurality of PCBs that are coupled together, in contrast with known coils constructed from only a single PCB. During a pre-assembly stage, three PCBs are coupled to one another in order to form a partial coil assembly structured to be mounted onto a circuit interrupter primary conductor. After the partial coil assembly is mounted onto the primary conductor, a fourth PCB is connected to the partial coil assembly via press-fit connectors to form a complete coil. In contrast with known PCB Rogowski coils which are structured to be mounted perpendicularly to the primary conductor, the disclosed modular PCB Rogowski coil enables a substantial portion of the PCB surface area to be mounted in parallel to the primary conductor and to thus occupy significantly less space than known PCB Rogowski coils.