Sensored Cable PCB Voltage Sensor Contact
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Solution Overview
Problem
Existing voltage sensors for power cables face issues with incomplete, corroded, or damaged electrical contacts, leading to inaccurate voltage readings due to poor contact points and increased electrical resistance, which can result in lower measurement accuracy.
Innovation Solution
A sensored cable design incorporating a printed circuit board (PCB) element with an exposed conductive region providing a large, extended two-dimensional surface contact area over an electrically isolated conductive or semiconductive material, ensuring multiple contact points and reducing resistive losses, thereby enhancing the accuracy and reliability of voltage measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single contact point is used between the PCB element and the conductive material, then the device complexity is reduced, but the reliability of electrical contact deteriorates due to corrosion, damage, or incomplete contact
Solution Approach 1:
The single contact point is segmented into multiple contact points distributed across the conductive material surface. The PCB element includes multiple contact pads that simultaneously contact different locations on the conductive material, dividing the contact function into multiple independent contact regions that reduce the impact of local corrosion or damage.
Solution Approach 2:
The contact interface is transitioned from a point contact (zero-dimensional) to a surface contact (two-dimensional). The PCB element's conductive layer extends over a surface area of the conductive material, creating multiple contact points across the surface rather than relying on a single point, thereby increasing contact reliability.
2Ease of manufacture
If a single contact location is used, then the manufacturing process is simplified, but the measurement precision deteriorates due to voltage drops from electron travel resistance
Solution Approach 1:
The voltage measurement function is segmented across multiple contact points on the PCB element. By distributing contact points across the conductive material surface, the path length for electron travel is reduced, minimizing voltage drops and improving voltage measurement accuracy while maintaining a relatively simple manufacturing process.
3Reliability
If multiple contact points are provided on the PCB element, then the reliability of voltage measurement is improved through redundancy, but the device complexity increases
Solution Approach 1:
Multiple contact points are merged into a single integrated PCB element structure. The conductive layer on the PCB element simultaneously provides multiple contact points while maintaining a unified structural design, achieving redundancy without proportionally increasing overall device complexity.
4Measurement precision
If the contact area is increased to provide multiple contact points, then the electrical resistance is reduced improving measurement accuracy, but the area of the PCB element increases
Solution Approach 1:
The PCB element is designed with non-uniform conductive layer distribution, concentrating conductive material in regions where contact with the cable's conductive layer is most effective. This localized quality approach increases contact area and reduces resistance in critical regions without proportionally increasing the overall PCB element area.
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 redundant contact points, reducing the risk of erroneous measurements and improving voltage reading accuracy by minimizing voltage drops and increasing the reliability of electrical contact with the conductive or semiconductive layer.
Implementation Method 1
the printed circuit board element being placed over an electrically isolated piece of conductive or semiconductive material... providing a large, extended two-dimensional surface contact area... ensuring multiple contact points and reducing resistive losses
Implementation Method 2
capacitive voltage sensor for sensing a voltage of the inner conductor... operable to form an electrode of a sensing capacitor of the capacitive voltage sensor
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
Sensored cable (1) for distribution of electrical power in a power network, the sensored cable comprising an inner conductor and an insulating layer (10) arranged concentrically around at least an axial section of the inner conductor. The sensored cable further comprises a capacitive voltage sensor (100) for sensing a voltage of the inner conductor, characterized by the sensor including a printed circuit board element (60), which is placed over an electrically isolated piece (140) of conductive or semiconductive material, arranged on the insulating layer of the cable. The electrically isolated piece (140) of conductive or semiconductive material is operable to form an electrode of a sensing capacitor of the capacitive voltage sensor. The cable may comprise a (semi-) conductive layer (20). The electrically isolated piece (40) of conductive or semiconductive material may comprise a portion of the (semi-) conductive layer.