Submersible Split Core Current Sensor Waterproof Housing
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Solution Overview
Problem
Existing split core current sensors face corrosion and other issues in outdoor, underground, or submerged applications, necessitating a solution for enhanced durability and reliability in such environments.
Innovation Solution
A submersible current sensor design featuring a split core current transformer with laminated high permeability cores and a waterproof resin-encapsulated housing, along with a pivotable and latchable housing mechanism, to protect the sensor from damage and allow for easy installation around conductors without disconnecting them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing split core current sensors are used in outdoor, underground or submerged applications, then current sensing capability is provided, but corrosion and other problems occur reducing reliability
Solution Approach 1:
The patent applies composite materials by combining a polymer housing material with waterproof resin encapsulation to create a composite protective structure. The housing is formed from a waterproof material that resists corrosion from water, moisture, and environmental factors, while the resin encapsulation adds an additional protective layer, creating a multi-material composite solution that prevents corrosion of the internal sensor components.
Solution Approach 2:
The patent creates a protected environment by sealing the sensor components within a waterproof housing and encapsulating them with resin. This creates an inert, corrosion-free environment inside the housing that isolates the sensitive electrical components from harmful external factors such as water, moisture, and corrosive substances in outdoor, underground, or submerged applications.
2Object-affected harmful factors
If a waterproof housing is added to protect the sensor, then corrosion resistance is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple protective functions into a single integrated housing structure. The housing combines the protective enclosure, the waterproof sealing mechanism, and the mounting structure for the sensor components into one unified assembly. This integration reduces the number of separate parts and assembly steps compared to using separate protective components.
Solution Approach 2:
The patent employs a polymer housing that provides flexible yet protective encapsulation of the sensor components. The housing material and resin encapsulation create a flexible yet durable protective shell that seals the components without requiring complex rigid structures, multiple fasteners, or intricate sealing mechanisms, thereby simplifying the overall device design.
3Strength
If the housing is made secure and waterproof, then protection from foreign objects is improved, but ease of installation decreases
Solution Approach 1:
The patent divides the housing into two separable halves that can be opened and closed around the conductor. This segmentation allows the housing to be opened for easy installation by sliding it over the conductor, then closed to provide secure, waterproof protection. The split-core design enables the housing to encircle the conductor without requiring disconnection or complex assembly procedures.
Solution Approach 2:
The patent incorporates a hinge mechanism that provides dynamic movement between the two housing halves, allowing the housing to transition from an open state during installation to a closed, secured state for operation. The hinge enables easy opening and closing actions while maintaining a secure, waterproof seal when closed, combining installation ease with protective strength.
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 durable and reliable current sensing capability in submerged conditions, preventing corrosion and damage from foreign objects while enabling easy installation, thus addressing the limitations of existing sensors.
Implementation Method 1
a first transformer part encapsulated by a first waterproof resin; and a second transformer part encapsulated by a second waterproof resin
Implementation Method 2
A submersible current sensor design featuring a split core current transformer with laminated high permeability cores
Data Source
AI summary
A submersible current sensor for sensing a current in a submerged conductor includes: a split core current transformer constructed to generate an output representative of the current carried by the conductor, the split core having a first core member, a first winding disposed about at least a portion of the first core member; a second core member; and a second winding disposed about at least a portion of the second core member; and a housing, the housing including: a first housing member constructed to house the first core member and the first winding; and a second housing member constructed to house the second core member and the second winding.