Two-Piece Ferromagnetic Core Current Sensor for Non-Invasive Monitoring
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Solution Overview
Problem
Conventional DC current sensors require invasive connections, are expensive, or have complex installations, necessitating the disconnection and re-wiring of high DC voltage and current, which is dangerous and inconvenient.
Innovation Solution
A non-invasive DC current sensor system using a two-piece ferromagnetic core that clamps over the wire to concentrate magnetic flux for measurement by a Hall effect sensor, allowing for easy installation without cutting or modifying the wire, and includes a current monitor control board with wireless communication capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional DC current sensors are used, then current measurement is achieved, but invasive connection and complex installation are required
Solution Approach 1:
The magnetic core is divided into two separate halves that can be independently positioned and clamped around the wire. This segmentation allows the sensor to be installed without disconnecting the wire, as the two halves can be placed on either side of the existing wiring and secured together, dramatically simplifying installation while maintaining measurement accuracy
Solution Approach 2:
The sensor housing and magnetic core are designed to clamp around the existing wire, effectively nesting the measurement device around the conductor without requiring the wire to pass through a hole or be disconnected. This nested configuration allows the sensor to capture the magnetic field generated by the current-carrying wire while leaving the electrical connection intact
2Measurement precision
If conventional DC current sensors are used, then current measurement is achieved, but wire disconnection and re-wiring is necessary
Solution Approach 1:
By dividing the magnetic core into two halves that clamp around the wire, the invention eliminates the need to disconnect the wire for installation. The segmented core can be positioned around the existing wiring while it remains connected, allowing installation without exposing workers to dangerous high voltage and current, thereby improving safety while maintaining measurement precision
Solution Approach 2:
The insulating housing acts as an intermediary barrier between the installer and the live electrical components. This protective enclosure allows the magnetic core to be positioned around the wire without direct contact with the conductor or insulation, enabling safe installation near high voltage areas without requiring wire disconnection
3Measurement precision
If conventional DC current sensors are used, then current measurement is achieved, but high cost is incurred
Solution Approach 1:
The divided magnetic core design allows for simpler manufacturing processes and the use of more cost-effective materials compared to conventional single-piece cores. The segmented structure can be produced using standard machining or molding techniques, and the simpler geometry reduces manufacturing complexity, thereby lowering production costs while maintaining the ability to accurately measure current through magnetic field detection
Solution Approach 2:
The sensor design employs cost-effective materials and construction methods that reduce manufacturing expenses. The housing uses standard insulating materials, the magnetic core can be made from conventional ferromagnetic materials, and the overall structure is designed for economical production, making the sensor more affordable while still providing accurate current measurement capability
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 safe, easy, and cost-effective measurement of DC or AC current without disrupting the electrical circuit, providing continuous monitoring of battery health and status with increased sensitivity and accuracy.
Implementation Method 1
A two-piece ferromagnetic core is clamped together over the wire by a housing to form a ferromagnetic cylinder that concentrates the magnetic flux surrounding the electrical wire to be measured
Implementation Method 2
By directing the magnetic flux to a Hall effect sensor, the DC or AC current can be measured
Data Source
AI summary
A current sensor includes a two-piece ferromagnetic core clamped together over a wire to be measured by a housing to form a ferromagnetic cylinder that concentrates the magnetic flux surrounding the electrical wire to be measured. By directing the magnetic flux to a Hall effect sensor, the current can be measured in the wire without cutting or modifying the wire.