Split-Core Current Sensor with Series-Linked Halfring Coils
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Solution Overview
Problem
Current split-core current sensing devices face challenges in achieving high accuracy due to unstable and non-round shapes, while more accurate designs are complex and costly, and there is a risk of interconnecting cable damage.
Innovation Solution
The design features a chain-like arrangement of at least two current sensors connected in series within a ring-shaped support, divided into two halfring-elements mechanically connected by a hinge, with interconnection cables allowing the device to open without disconnecting the circuit, and a conductive housing for shielding, enabling high accuracy and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible coil design with openable locking mechanism is used, then ease of assembly is improved, but measurement precision deteriorates due to unstable and non-round shape
Solution Approach 1:
The flexible coil is segmented into multiple discrete linear coils connected in series, with each coil housed in its own housing element. This segmentation allows the coil assembly to be divided into two halfring-elements that can be opened using a hinge mechanism, maintaining ease of assembly while improving shape stability for accurate measurement.
2Measurement precision
If two solid halves with electrical connectors are used, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses flexible housing elements that can be divided into two halfring-elements connected by a hinge, allowing the device to open like a book. This flexible shell approach maintains measurement precision through stable coil positioning while simplifying assembly and reducing complexity compared to rigid connector-based designs.
3Measurement precision
If two solid halves with external cable interconnection are used, then measurement precision is improved, but reliability deteriorates due to increased risk of cable damage
Solution Approach 1:
The electrical interconnection between the two halfring-elements is merged into the housing structure itself through integral connection points and sealed cable conduits. This eliminates external vulnerable cables while maintaining the precision measurement capability, significantly improving reliability.
4Measurement precision
If linear coils are arranged with equal gaps in series, then measurement precision is improved, but manufacturing complexity increases
Solution Approach 1:
The linear coils are pre-assembled with equal gaps in a standardized configuration within each housing element before the final assembly into the halfring-elements. This preliminary preparation simplifies the overall manufacturing process while ensuring the precise equal-gap arrangement necessary for accurate measurement.
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 measurement accuracy, simplifies assembly, and reduces the risk of cable damage while maintaining a cost-effective and robust design by allowing direct mounting on measurement sites without disassembling the circuit.
Implementation Method 1
the housing of said linear coils is either made of at least partly conductive material or has at least partly conductive inner or outer surface treatment
Implementation Method 2
the current sensors are at least partly linear coils
Data Source
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AI summary
The invention relates to a Current sensing device with at least two current sensors, implemented in an openable ringshaped support, and a method of manufacture the same, according to the preamble of the claims 1 and 11. In order to optimize the current sensor device in the structural shape, in order to enhance the manufacturing, by resulting high accuracy. This is realized by the invention in such, that more than two current sensors are arranged in a chain-like arrangement in the ringshaped support, and that the current sensors are electrically connected in series.