Non-Invasive Current Sensor Magnetic Core Protective Case
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Solution Overview
Problem
Existing non-invasive current sensors face accuracy and reliability issues due to environmental factors such as temperature and humidity changes, which affect the measurement of magnetic fields near current-carrying conductive wires, particularly in applications like electric vehicles where sensors are exposed to varying conditions.
Innovation Solution
The proposed solution involves a non-invasive current sensor apparatus with a magnetic core concentrator and a protective case filled with an adhesive substance, housing a sensing element, which is designed to isolate the sensing device from environmental changes, ensuring accurate and reliable measurements by concentrating the magnetic field and protecting the sensor from external influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the sensing element is exposed to the external environment for easy access and assembly, then the ease of operation is improved, but the reliability of magnetic field measurement deteriorates due to environmental factors such as temperature and humidity changes
Solution Approach 1:
The sensing element is nested within a protective case, which is in turn nested within the housing structure. This nested configuration allows the sensing element to be protected from environmental factors while still enabling access through the case opening, thus resolving the contradiction between protection and ease of assembly.
Solution Approach 2:
A protective case is introduced as a flexible enclosure around the sensing element. This protective case can be easily assembled and disassembled while providing sufficient protection against environmental factors like temperature and humidity, maintaining both ease of operation and measurement reliability.
2Reliability
If the sensing element is protected from environmental factors, then the reliability of measurement is improved, but the device complexity increases due to additional protective structures
Solution Approach 1:
The device is segmented into distinct functional modules: the sensing element, the protective case, and the housing. This segmentation allows each component to perform its specific function independently, reducing overall complexity while maintaining protection. The protective case is a separate, removable component that can be easily assembled and disassembled.
Solution Approach 2:
The protective case serves as a simple yet effective protective structure that does not significantly increase device complexity. It provides necessary protection while maintaining ease of assembly and disassembly, thus balancing protection requirements with structural simplicity.
3Ease of repair
If the protective case is made removable for easy maintenance, then the ease of repair is improved, but the reliability may deteriorate due to potential loosening or misalignment
Solution Approach 1:
The protective case is designed with preliminary alignment features and attachment mechanisms that ensure proper positioning and secure attachment before use. This preliminary action prevents loosening and misalignment during operation, while still allowing easy removal for maintenance, thus resolving the contradiction between ease of repair and reliability.
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 configuration enhances the accuracy and reliability of current measurements, allowing for higher resolution and longer usability of non-invasive current sensors by shielding the sensing element from environmental variances and enabling easy disassembly and maintenance.
Implementation Method 1
a magnetic core having a first end and a second end, wherein the magnetic core may be formed into a substantially complete perimeter comprising a center opening, and wherein an air gap may be defined between the first end and the second end of the magnetic core
Implementation Method 2
a second housing comprising a sensing element. The sensing element may be positioned such that in an instance in which the first housing is attached to the second housing, the protective case receives the sensing element
Data Source
AI summary
A non-invasive current sensor and a method for assembling the non-invasive current sensor are provided. An example non-invasive current sensor may include a first housing, the first housing including a magnetic core having a first end and a second end and a protective case. The magnetic core may be formed into a substantially complete perimeter having a center opening, and defining an air gap may between the first end and the second end of the magnetic core. The first housing may further include a protective case disposed in the air gap of the magnetic core. In addition, the non-invasive current sensor may include a second housing having a sensing element. The sensing element may be positioned such that in an instance in which the first housing is attached to the second housing, the protective case receives the sensing element.