Split-Core Circuit Submetering for Non-Disruptive Panel Retrofit
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Solution Overview
Problem
Traditional electrical power measurement systems in service panels cannot separately measure power usage for individual circuits, requiring disruptive and costly installations to retrofit sensors, which disrupt power distribution and are time-consuming.
Innovation Solution
A ganged current sensor system using split ferrite cores and Rogowski coils, designed to fit around conductors without disconnecting them from circuit breakers, allowing for wireless communication of current measurements and energy harvesting, enabling precise monitoring of individual circuit power usage without disrupting the power infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sensors are installed in service panels to measure individual circuit power usage, then measurement capability is improved, but installation complexity and disruption increase
Solution Approach 1:
The service panel is divided into individual circuit locations, with each circuit breaker position equipped with a separate current sensor. This segmentation allows independent measurement of each circuit's power consumption without requiring a complete system overhaul or complex wiring modifications across the entire panel.
Solution Approach 2:
The current sensor design integrates multiple functions into a single device: it measures current for power calculation, provides over-current protection detection, and enables circuit identification. This multi-functionality reduces the number of separate components needed and simplifies the overall installation process while maintaining comprehensive monitoring capabilities.
2Measurement precision
If traditional sensors are installed in service panels to measure individual circuit power usage, then measurement capability is improved, but installation time increases
Solution Approach 1:
The current sensors are pre-configured with circuit identification data and measurement parameters before installation. This preliminary preparation allows the sensors to be quickly installed and immediately begin providing accurate circuit-by-circuit power measurements without requiring time-consuming on-site configuration or calibration procedures.
Solution Approach 2:
The system automatically identifies circuits and associates measurements with the correct circuit breakers without requiring manual intervention. The sensors self-configure based on their physical location in the service panel, eliminating the need for technicians to manually program each sensor and significantly reducing installation time.
3Measurement precision
If disruptive installation methods are used to retrofit sensors, then measurement capability is improved, but system reliability during installation decreases
Solution Approach 1:
The current sensors are installed as intermediary devices that clamp around existing conductors without requiring disconnection from circuit breakers or modification of the power distribution system. This intermediary approach allows measurement capability to be added while maintaining the integrity and continuity of the existing power distribution infrastructure throughout the installation process.
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
Enables efficient, non-disruptive installation and continuous monitoring of electrical power usage for each circuit, reducing installation costs and minimizing downtime, while providing accurate data on energy consumption and other electrical parameters.
Implementation Method 1
the first component includes a first portion of an inductive energy harvesting device proximal to the first side of the opening
Implementation Method 2
a first portion of a current sensing device, different than the inductive energy harvesting device
Data Source
AI summary
A current sensor includes a first component and a second component shaped to fit together to create a combined unit with multiple openings through the combined unit. The opening is bounded on a first side by the first component and on a second side by the second component. The first component and the second component are configured to be fitted together around current-carrying conductors passing through the openings. The first component includes first portions of an inductive energy harvesting device and a current sensing device, both proximal to the first side of the opening. The second component includes second portions of the inductive energy harvesting device the current sensing device, both proximal to the second side of the opening. The inductive energy harvesting device may include a split-core ferrite current transformer and the current sensing device may include a Rogowski coil.