Segmented Rogowski Coil Manufacturing via Modular Assembly
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Solution Overview
Problem
Current sensing devices, including Rogowski coils, face challenges in manufacturing due to complex coil configurations, leading to high costs and potential errors, while existing solutions fail to offer both low manufacturing costs and improved electrical performance.
Innovation Solution
The development of segmented winding elements and form-less air coils with a return conductor that couples leading and trailing segments, allowing for flexible assembly and tuning, enabling scalable and cost-effective current sensing devices with improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional Rogowski coils are manufactured using complex winding configurations, then electrical performance is improved, but manufacturing cost and labor intensity increase significantly
Solution Approach 1:
The Rogowski coil is divided into multiple discrete segments or modules, each containing a portion of the total windings. These segments can be manufactured separately using standardized processes and then assembled together to form the complete coil. This segmentation enables modular manufacturing, reducing labor intensity and improving consistency while maintaining the electrical performance of the complete coil structure.
2Measurement precision
If traditional Rogowski coils use complex winding configurations, then measurement precision is improved, but manufacturing complexity and error potential increase
Solution Approach 1:
The complex winding configuration is broken down into multiple simpler segments, each with a manageable number of turns and straightforward winding patterns. This reduces the complexity of individual manufacturing steps and minimizes errors during assembly, while the collective arrangement of segments achieves the required measurement precision through proper geometric distribution and coupling.
Solution Approach 2:
Different segments of the Rogowski coil can be optimized for local requirements, with variations in winding density, turn count, or geometric parameters tailored to specific positions along the coil. This allows precise control of magnetic field sampling at different locations, improving overall measurement accuracy while keeping each local segment relatively simple to manufacture.
3Productivity
If Rogowski coils are made with standardized modular segments, then manufacturing scalability is improved, but device complexity increases
Solution Approach 1:
The Rogowski coil is designed as an assembly of standardized modular segments that can be manufactured using consistent processes and then systematically assembled. Each module contains integrated connection terminals and alignment features that simplify the assembly process, enabling scalable production while keeping the assembly procedure relatively simple through repetition of identical units.
Solution Approach 2:
Multiple functional elements are combined within each modular segment, including windings, support structures, connection terminals, and alignment features. This integration reduces the number of separate components that need to be assembled and minimizes interconnection complexity, allowing scalable manufacturing without proportionally increasing assembly complexity.
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 approach results in low-cost, precise, and scalable current sensing devices that can be tuned for optimal performance, reducing manufacturing complexities and errors while maintaining high electrical performance.
Implementation Method 1
The voltage that is induced in the coil is proportional to the rate of change of current in the conductor such that the output of the Rogowski coil is indicative to the amount of current passing through the conductor.
Data Source
AI summary
A low-cost and high-precision current sensing device and methods for use and manufacturing. In one embodiment, the current sensing apparatus comprises a Rogowski-type coil which is manufactured in segments so as to facilitate the manufacturing process. In an exemplary embodiment, the current sensing apparatus segments comprise a number of bobbin elements that are wound and subsequently formed into complex geometric shapes such as torus-like shapes. In an alternative embodiment, bonded windings are utilized which allow the segments to be formed without a bobbin or former. In yet another alternative embodiment, the aforementioned current sensing devices are stacked in groups of two or more. Methods of manufacturing and using the aforementioned current sensing apparatus are also disclosed.