Split-Core Current Transducer With Integrated Magnetic Detector
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Solution Overview
Problem
Existing electrical current transducers without a magnetic core face challenges in reliability, sensitivity, accuracy, and operating range, making them less effective for high-power applications, and their separate manufacturing on circuit boards is not optimal in terms of size and weight.
Innovation Solution
An integrated electrical current transducer design featuring a U-shaped magnetic core with a magnetic field detector module, where the magnetic field detector module is positioned between the lateral branches of the magnetic core, allowing for compact, cost-effective, and reliable current measurement with a large operating range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic core is used to improve reliability, sensitivity, accuracy and operating range, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The magnetic core is divided into two separate parts (first and second magnetic core parts) that can be assembled around the primary conductor in a split configuration. This segmentation allows the transducer to maintain high measurement precision through the magnetic core while reducing assembly complexity and enabling easier installation on existing conductors.
Solution Approach 2:
A non-magnetic support structure serves as an intermediary component that holds the two magnetic core parts in the correct relative position and spacing. This intermediary element simplifies the overall assembly process by providing a pre-fabricated framework that ensures proper alignment and gap maintenance between magnetic core parts without requiring complex adjustment procedures.
2Measurement precision
If a magnetic core is used to improve sensitivity and accuracy, then measurement precision is improved, but weight and size increase
Solution Approach 1:
The magnetic core is segmented into two separate parts that can be positioned on opposite sides of the primary conductor. This segmentation reduces the total volume of magnetic material required compared to a complete encircling core, thereby reducing weight while maintaining sufficient magnetic flux path for accurate measurement. The split configuration allows the magnetic core parts to be thinner and lighter.
Solution Approach 2:
The transducer transitions from a traditional planar mounting approach to a three-dimensional split-core configuration that wraps around the primary conductor. This dimensional change allows the magnetic core to achieve effective magnetic coupling with the conductor using less material, reducing weight while maintaining measurement sensitivity through the magnetic flux path established in the three-dimensional arrangement.
3Ease of manufacture
If separate manufacturing of transducer components is used to simplify production, then ease of manufacture is improved, but assembly complexity and time increase
Solution Approach 1:
The magnetic core is manufactured as separate modular parts that can be independently produced using standard manufacturing processes. These segmented components are designed with complementary features (such as protrusions and recesses, or keyed interfaces) that enable rapid and unambiguous assembly around the primary conductor, reducing assembly time despite the multi-component nature of the design.
Solution Approach 2:
The non-magnetic support structure is pre-assembled with the two magnetic core parts in their correct relative positions and orientations before installation on the primary conductor. This preliminary assembly action ensures that when the complete transducer is installed, the components are already aligned and spaced correctly, significantly reducing on-site assembly time and complexity.
4Adaptability or versatility
If a complete encircling magnetic core is used to improve measurement range, then operating range is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The magnetic core is divided into two parts that can be positioned on opposite sides of the primary conductor, creating a split-core configuration. This segmentation maintains the magnetic flux path necessary for measuring a wide range of currents (including high currents) while simplifying the structure compared to a solid encircling core. The segmented design can accommodate larger conductors and higher current densities without requiring a proportionally larger or more complex core structure.
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 solution provides a compact, reliable, and cost-effective electrical current transducer with improved accuracy and sensitivity, enabling efficient current measurement across a wide range while simplifying assembly and integration on circuit boards.
Implementation Method 1
a magnetic core and a magnetic field detector in an air-gap of the magnetic core, for measuring an electrical current flowing in a primary conductor extending through a central passage of the magnetic core
Implementation Method 2
the magnetic field detector module comprises at least one magnetic field sensing cell
Data Source
AI summary
An electrical current transducer including a magnetic core and a magnetic field detector module, the magnetic core and magnetic field detector module each forming a single unit separably mountable around a primary conductor and to a circuit board, the magnetic core having a general U shape including an end branch and lateral branches extending the end branch to respective free ends, the magnetic field detector module being positioned between the lateral branches and extending across a whole width of a gap formed between the lateral branches. The magnetic field detector module includes at least one magnetic field sensing cell, a pair of magnetic concentrators arranged in mirror opposition forming a magnetic field gap therebetween in which the at least one sensing cell is positioned, and an insulating body supporting the magnetic concentrators and at least one sensing cell.