"current sensing devices and methods"

专利摘要:
"CURRENT SENSORS DEVICES AND METHODS". The present invention relates to low cost and high precision current sensing device and methods for use and fabrication. In one embodiment, the current sensing apparatus comprises a Rogowski coil, which is manufactured in segments in order to facilitate the manufacturing process. In an exemplary embodiment, the segments of the current sensing apparatus comprise a number of coil elements that are wound and subsequently formed into complex geometrics, such as tor-like shapes. In an alternative embodiment, bonded windings are used which allow the segments to be formed without a coil or former. In yet another alternative embodiment, the aforementioned current sensing devices are stacked in groups of two or more. Methods of fabrication and using the aforementioned current sensing apparatus are also disclosed.
公开号:BR112012016902A2
申请号:R112012016902-5
申请日:2011-01-06
公开日:2021-04-20
发明作者:James Douglas Lint；Fuxue Jin；Francisco Michel；Victor Aldaco
申请人:Pulse Electronics, Inc.；
IPC主号:

专利说明:

Descriptive Report of the Patent of Invention for "DEVICES OF CURRENT SENSORS AND METHODS". Priority The present application claims priority to United States Patent Application Serial No. 12/954,546, filed November 24, 2010, of the same title, which is a continuation in part of and claims priority to the Application US Patent Serial No. 12/684,056, filed January 7, 2010, of the same title, which is a continuation in part of and claims priority to US Patent Application Serial No. 12/567,622 , filed September 25, 2009, of the same title, which claims priority to United States Patent Application Serial No. 61/230,474, filed July 31, 2009, of the same title, each of which is here incorporated atra-. See reference in its entirety. Copyright ' A portion of the description in this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent description, as it appears in the patent files or records of the Department of Patents and Trademarks for Industry and Commerce, but , otherwise, reserves all copyrights, whatever they may be.
1. Field of the Invention The present invention relates generally to circuit elements, and more particularly, in an exemplary aspect, to devices for detecting current and methods of using and fabricating the same. Related Technology Description. A myriad of different configurations of current sensing devices are known in the prior art. A common approach to manufacturing current sensing devices is via the use of a so-called "Rogowski coil". A Rogowski coil is a device |
' electrical for the measurement of alternating current ("AC"), It consists, tipica- ; of a helical wire coil with the conductor from one end returning through the center of the coil and passing through the coil of wire to the other end. The entire helical wire coil is then placed around an alternating current carrying conductor whose current is to be measured. The voltage that is induced in the coil is proportional to the rate of current change in the conductor so the output of the Rogowski coil is indicative of the amount of current passing through the conductor. Rogowski coils can be made open-ended and flexible, allowing them to be wound around a current-carrying conductor without otherwise directly disturbing the current passing through that conductor. A Rogowski coil typically uses air rather than a magnetically permeable core, thus giving the Rogowski coil the properties of a relatively low inductance along with the response to relatively fast changing currents. Furthermore, the output of a Rogowski coil is typically highly linear, even when subjected to large currents, such as those used in electrical power transmission, welding, or other pulsed power applications. In addition, properly constructed Rogowski coils are often also largely immune to electromagnetic interference, thus making them resistant to external tampering. However, due to the relatively complex winding configurations, prior art attempts to manufacture Rogowski coils have proved to be very labor intensive.
There are numerous methodologies for producing Rogowski coils in the prior art, including, for example, those disclosed in U.S. Patent No. 4,616,176, to Mercure et al., issued October 7, 1986 and entitled "Dynamic current transducer "; United States Patent No. 5,414,400, to Gris et al., issued May 9, 1995 and entitled "Rogowski coil", United States Patent No. 5,442,280, to Baudart, issued August 15, 1995 and titled "Device for measuring |
' an electrical current in a conductor using a Rogowski coil"; U.S. Patent No. 5,982,265, to Von Skarczinski, et al., issued November 9, 1999 and entitled "Current-detection coil for a current transfor - mer"; United States Patent No. 6,094,044, to Kustera, et al., issued July 25, 2000 and entitled "AC current sensor having high accuracy and large bandwidth"; United States Patent No. 6,313,623, to Kojovic, et al., issued November 6, 2001 and entitled "High precision Rogowski coil"; United States Patent Serial No. 6.614,218, to Ray, issued September 2, 2003 and entitled "Current measuring device" ; United States Patent No. 6,731,193, to Méier, et al., issued on May 4, 2004 and entitled "Printed circuit board-based current sensor"; United States Patent No. 6,822,547, to Saito, et al., issued November 23, 2004 and entitled "Current transformer"; United States Patent No. 7,227,441, of Sk endzic, et al., issued June 5, 2007 and entitled "Precision Rogowski coil and method for manufacturing same"; United States Patent No. 7,253,603, to Kovanko, et al., issued August 7, 2007 and entitled "Current sensor arrangement"; United States Patent No. 7,538,541, to Kojovic, issued 26 of May 2009 and entitled “Split Rogowski coil current measuring device and methods”; United States Patent Publication No. 20050248430, to Dupraz, et al., published on November 10, 2005 and entitled “Current transformer with Rogowski type windings comprising an association of partial circuits forming a complete circuit"; United States Patent Publication No. 20060220774, by Skendzic, published October 5, 2006 and entitled "Precision printed circuit board based Rogowski coil and method for manufacturing same ", U.S. Patent Publication No. 20070290695, of Mahon, published December 20, 2007 and entitled "Method and Apparatus for Measuring Current"; U.S. Patent Publication No. 20080007249, of Wilkerson, et al. ., published January 10, 2008 and entitled "Precision, Temperature-compensated, shielded current measurement device"; a to United States Patent Publication No. 20080079418, by Rea, et al., published April 3, 2008 and
| side "High-precision Rogowski current transformer"; a United States Patent Publication No. 20080106253, by Kojovic, published May 8, 2008 and entitled "Shielded Rogowski coil assembly and methods"; and United States Patent Publication No. 20080211484, by HO-WELL, et al, published September 4, 2008 and entitled "Flexible current transformer assembly".
Despite the wide variety of prior art current sensor configurations, there is a pressing need for current sensing devices (including Rogowski coils) that are of low cost to manufacture, this low cost being allowed for by addressing inter alia the difficulties associated with the complex configurations of the coils of prior art current sensing devices, and offer improved or at least comparable electrical performance. to prior art devices. Ideally, this solution would not only offer very low manufacturing cost and improved electrical performance for the current sensing device, but would also provide a high level of performance consistency and reliability by limiting opportunities for errors or other imperfections. during device manufacture.
Furthermore, an ideal solution would also be at least somewhat scalable and capable of taking on many desired form factors. Summary of the Invention In a first aspect, an inductive current sensing device is disclosed. In one embodiment, an inductive current sensing device includes multiple segmented winding elements. A return conductor electrically couples a front of the segmented winding elements with a rear of the segmented winding elements.
In one embodiment, the segmented winding elements comprise segmented coil elements in which a number of windings are arranged.
In another modality, the windings are effectively self- | nomos, so that no coil or other internal support structure is required. In a second aspect of the invention, an improved formless inductive current sensing device is disclosed. In one embodiment, the inductor device includes multiple formless coiled air coils. These air coils are then placed into respective cavities located in an encapsulation tube. A return conductor couples a front of the formless coils with a rear of the formless coils.
In a third aspect of the invention, a system apparatus incorporating the aforementioned inductive current sensing devices is disclosed. In one embodiment, the system apparatus comprises a power distribution utility box that incorporates a device. Improved inductive current sensor. The power distribution utility box includes a network interface that transmits data collected by the inductive current sensing device through a network to a device or location (eg, centralized repository or control center) for monitoring, billing. and/or control applications. In a fourth aspect of the invention, methods of manufacturing the aforementioned device(s) are disclosed. In one embodiment, the method comprises continuously winding an insulated conductor across multiple segmented coil elements. A return conductor is routed between each of the segmented coil elements. The return conductor is then electrically coupled with the insulated conductor to form the inductive current sensing device.
In a fifth aspect of the invention, methods of using the aforementioned apparatus are disclosed.
In a sixth aspect of the invention, a scalable inductor device is disclosed. In one embodiment, the device comprises a number of winding segments (and/or number of turns per segment) that can be varied, as desired, so as to obtain a desired trade-off between higher performance and higher manufacturing cost.
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In a seventh aspect of the invention, a low cost and highly accurate inductive device is disclosed. In one embodiment, a number of segments are used to effectively approach a continuous, circular Rogowski coil device.
In an eighth aspect of the invention, a user-adjustable set of multicoils is disclosed. In one embodiment, two or more segmented coils are stacked (i.e., juxtaposed with a common central geometric axis), so that the annular arrangement (rotation) of the coils about the common axis can be varied by an installer or end user and/or the number of coils present can be changed. As the segments of one coil are placed in a different position relative to the segments of the other coil(s) (and/or the number of coils increased or decreased), the output of the devices will vary, at- . yes, allowing the installer/user to "tune" the actual output of the coil set to the desired level of performance.
In another embodiment, the two or more coils are substantially concentric with each other so that they have different radii. Similarly, when the relative position of the coils is changed (and/or the number of coils varied), the output of the coils will also vary and can be tuned or adjusted to a desired level of performance.
Furthermore, in yet another modality, the spacing or vertical arrangement of the different coils (either in a "stacked" or "concentric" configuration) can be varied, thus increasing/decreasing the coupling or interaction of the coils.
In a ninth aspect of the invention, a coil device having a conductor receive insert. In one embodiment, the device comprises a segmented coil of the type referenced above, which further includes a central portion adapted to guide and place one or more conductors being monitored at a prescribed location within the central region of the coil.
In a tenth aspect of the invention, a support structure | for use with the aforementioned inductive current sensing devices is disclosed. In one embodiment, the support structure includes multiple coil elements. At least a portion of the coil elements also include connection features that are used to join a coil element to an adjacent coil elements. In an eleventh aspect of the invention, a coil element for use in inductive current sensing devices mentioned is disseminated. In one embodiment, the coil element includes a spool element, which defines an interior volume and further having an outer winding diameter associated with the spool element. A pair of flange features are also disposed at opposite ends of the spool element.
In one variant, at least one of the flange feature pair . includes an electrically conductive clip disposed therein. In yet another variant, the interior volume includes a return conductor support feature that positions a return conductor in a predetermined position with respect to the spool member.
In a twelfth aspect of the invention, an inductive current sensing device is disclosed. In one embodiment, the device comprises: a plurality of coil elements, each element having one or more terminals with a conductive winding wound thereon; and a printed circuit board with an opening therein. The plurality of coil elements are arranged around the opening and the elements are electrically coupled together via a printed circuit board.
In a variant, the device further comprises: a return conductor which electrically couples a front of the plurality of coil elements with a rear of the coil elements.
In another variant, at least two of the plurality of coil elements are physically coupled together via a hinged coupling.
In yet another variant, at least three of the plurality of coil elements are physically coupled together via one or more of | a plurality of articulated couplings, respectively, with a first articulated coupling disposed on a first side of a winding channel of a first coil element and a second articulating coupling disposed on a second side of the winding channel of the first coil element .
In another variant, each of the coil elements comprises a pair of flanges with a winding spool substantially disposed between them, the conductive winding wound on the winding spool. One or more terminals comprise, for example, self-conducting terminals incorporated into at least one sidewall of at least one of the pair of flanges.
In yet another variant, the plurality of coil elements comprises three or more coil elements, with a start and an end portion of the conductive winding being disposed at a non-end of the three or more coil elements.
In another variant, the conductive winding comprises a plurality of layers disposed on one or more of the winding cylinders of the coil elements and at least one of the layers comprises a shielding layer operative to mitigate the effects of a single cam. external electromagnetic po.
In another variant, the plurality of layers comprises: two or more armor layers; and two or more current sensing layers. The two or more shield layers and the two or more current sensing layers are interspersed with each other.
In another embodiment, the inductive current sensing device comprises: a plurality of linearly wound inductive elements, each element comprising: a pair of flanges; a plurality of layers of conductive winding disposed in the winding channel; and one or more articulation resources; and an accommodation comprising a driver receiving opening. The plurality of linearly wound inductive elements are collectively disposed around the conductor receiving opening in a substantially alternating or zigzagging fashion.
Zag.
In a variant, at least one of the plurality of winding layers comprises a shielding layer and the winding direction for the shielding layer alternates between adjacently arranged linearly wound inductive devices.
In another variant, the conductor receiving opening includes an integrated conductor which must be detected by linearly wound inductive elements.
In another variant, the housing further comprises a plurality of terminals for electrically interfacing with a printed circuit board.
In yet another variant, the housing includes a plurality of alignment features which arrange the inductively wound elements linearly in alternating or zigzag mode when linearly wound inductive elements are received therein.
In a thirteenth aspect of the invention, a method of manufacturing an inductive current sensing device is disclosed. In one embodiment, the method comprises: attaching a first end of a conductive winding to one of a plurality of segmented winding elements; continuously winding the conductive winding onto a plurality of segmented winding elements in a sequential order, and attaching the second end of the conductive winding to one of the plurality of segmented winding elements.
In a variant, the first end and the second end of the attached conductive winding are attached to one of the plurality of segmented winding elements. The sequential order comprises, for example, traversing from the middle of one of the plurality of segmented winding elements to a first end segmented winding element of the plurality of segmented winding elements; traverse from the first end segmented winding element of the plurality of segmented winding elements to one | second end segmented winding element of the plurality of segmented winding elements; and traversing the second end segmented winding element of the plurality of segmented winding elements back into the middle of one of the plurality of segmented winding elements.
In another variant, the act of attaching the first end comprises terminating the conductive winding on a self-conducting terminal present on one of the plurality of segmented winding elements.
Brief Description of the Drawings The aspects, objectives and advantages of the invention will become more evident from the detailed description presented below, when taken in conjunction with the drawings, in which: - Figure 1 is a perspective view illustrating a first embodiment of a device. Rogowski coil in accordance with the principles of the present invention.
Figure 1A is a perspective view of the coil head of Figure 1, in accordance with the principles of the present invention.
Figure 1B is a sectional perspective view taken along line 1B-1B of Figure 1A.
Figure 1C is a perspective view illustrating a Rogowski coil formed by the segmented or continuous application of an adhesive in accordance with the principles of the present invention.
Figure 1D is an elevation view illustrating a field-installable Rogowski coil device with overlapping conductive ends in accordance with Rogowski coil principles.
Figure 1E is an elevational view illustrating a field-installable Rogowski coil device with bearing conductive ends in accordance with Rogowski coil principles. Figure 2 is a perspective view illustrating a portion of a second embodiment of a device. Rogowski coil in accordance with the principles of the present invention. |
Figure 2A is a sectional perspective view taken along line 2A-2A of figure 2.
Figure 2B is a perspective view of a single Rogowski coil segment, as illustrated in Figure 2, in accordance with the principles of the present invention.
Figure 2C is a perspective view of the single Rogowski coil segment illustrated in Figure 2B, shown from a different perspective.
Figure 3 is a perspective view illustrating a single Rogowski coil segment for a third embodiment of a Rogowski coil device in accordance with the principles of the present invention.
Figure 3A is a side elevational view of the Rogowski coil segment shown in Figure 3. Figure 3B is a perspective view illustrating four (4) Rogowski coil segments assembled as shown in Figure 3, forming one half of a Rogowski coil device in accordance with the principles of the present invention.
Figure 3C is a perspective view illustrating the four (4) Rogowski coil segments of Figure 3B, mounted on a winding mandrel, in accordance with the principles of the present invention.
Figure 3D is a side elevation view of the Rogowski coil segments mounted on the winding mandrel shown in Figure 3Cc.
Figure 4 is a perspective view illustrating a single Rogowski coil segment for a fourth embodiment of a Rogowski coil device in accordance with the principles of the present invention.
Figure 4A is a perspective view illustrating two wound Rogowski coil segments, as illustrated in Figure 4, mounted between two head segments in accordance with the principles of the present invention.
Figure 4B is a perspective view illustrating eight (8) sec- | Rogowski coil assemblies of Figure 4, with mounting on a winding mandrel in accordance with the principles of the present invention.
Figure 5 is a perspective view illustrating a single segment of Rogowski coil for a fifth embodiment of a Rogowski coil device in accordance with the principles of the present invention.
Figure SA is a side elevation view illustrating the single Rogowski coil element of Figure 5.
Figure 5B is a perspective view illustrating two Rogowski coil segments mountable together in accordance with the principles of the present invention.
Figure 5C is a perspective view illustrating eight (8) Rogowski coil segments mounted on a winding mandrel in accordance with the principles of the present invention.
Figure 6 is a perspective view illustrating a single Rogowski coil segment for a sixth embodiment of a Rogowski coil device in accordance with the principles of the present invention.
Figure 6A is a side elevation view illustrating the single member of the Rogowski coil of Figure 6.
Figure 6B is a perspective view illustrating two segments of the Rogowski coil of Figure 6, mountable together, in accordance with the principles of the present invention.
Figure 6C is a perspective view illustrating another embodiment of a coil segment adapted to receive a peripheral strand, in accordance with the principles of the present invention.
Figure 7 is a side elevation view illustrating various positions for passage through the conductor of a current sensing device, in accordance with the principles of the present invention.
Figure 8 is a top elevation view illustrating an alternative configuration for a Rogowski coil device positioned around a rectangular power conductor, in accordance with the principles of the present invention.
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Figure 8A is a top elevation view illustrating a first exemplary embodiment of the Rogowski coil device of Figure 8 with built-in alignment features to prevent drift and tilt, in accordance with the principles of the present invention.
Figure 8B is a top elevation view of another embodiment of the sensor device of the invention, adapted for use in a 4-sided (eg rectangular) collector bar (with cover removed).
Figure 8B-1 is a cross-section of the device of Figure 8B. taken along line 8B —1-8B —1, with cover installed.
Figure 9 is a side elevation view illustrating an alternative configuration for a Rogowski coil device in accordance with the principles of the present invention.
Figure 10 is a process flow diagram for manufacturing the current sensing apparatus of Figures 1 - 1B, in accordance with the principles of the present invention.
Figure 11 is a process flow diagram for manufacturing the current sensing apparatus of Figures 2-2C and Figures 4-4B in accordance with the principles of the present invention.
Figure 12 is a process flow diagram for manufacturing the current sensing apparatus of Figures 3-3D, in accordance with the principles of the present invention.
Figure 13 is a process flow diagram for manufacturing the current sensing apparatus of Figures 5-5C in accordance with the principles of the present invention.
Figure 14 is a process flow diagram for manufacturing the current sensing apparatus of Figures 6-6B in accordance with the principles of the present invention.
Figure 15A is a perspective view of a stacked Rogowski coil device in accordance with the principles of the present invention.
Figure 15B is an end elevational view of the stacked Rogowski coil device of Figure 15A.
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Figure 15C is a perspective view of a tunable implementation of the stacked Rogowski coil device of Figure 15A.
Figure 15D is a sectional perspective view of a second exemplary embodiment of a tunable stacked Rogowski coil device, in accordance with the principles of the present invention.
Figure 15E is an end elevational view of a concentrically stacked Rogowski coil device in accordance with the principles of the present invention. Figure 16 is a perspective view illustrating a portion of a seventh embodiment of a coil segment of Rogowski, in accordance with the principles of the present invention.
Figure 16A is a perspective view illustrating the Rogowski coil segment of Figure 16, joined together with other similar segments to form a Rogowski coil device. Figure 16B is an exploded perspective view of the seventh embodiment of a Rogowski coil and housing device.
Figure 16C is a sectional view taken along line 16C-16C of Figure 16B.
Figure 16DS is an end elevational view of the bottom portion of the housing associated with the Rogowski coil device illustrated in Figure 16B.
Figure 17 is a perspective view illustrating an eighth embodiment of a Rogowski coil segment, in accordance with the principles of the present invention.
Figure 17A is a perspective view illustrating the Rogowski coil segment of Figure 17 connected together with other similar segments to form a Rogowski coil device.
Figure 17B is a sectional view taken along line 17B-17B of figure 17A Figure 18A is a perspective view illustrating the insertion of the initial clip for a Rogowski coil segment, according to a | embodiment of the present invention.
Figure 18B is a perspective view illustrating the insertion of the final clip for a Rogowski coil segment, in accordance with an embodiment of the present invention.
Figure 18C is a perspective view illustrating insertion of Rogowski coil segments into a winding mandrel in accordance with an embodiment of the present invention.
Figure 19D is a perspective view illustrating the installation of the core assembly in the grooves of the coil segment, in accordance with an embodiment of the present invention.
Figure 18E is a perspective view illustrating the beginning of an embodiment of the winding process, in accordance with the principles of the present invention.
Figure 18F is a cross-sectional view illustrating layered windings disposed on the first Rogowski coil segment, in accordance with an embodiment of the present invention.
Figure 18G is a perspective view illustrating the passage of the winding between Rogowski coil segments, in accordance with an embodiment of the present invention.
Figure 18H is a perspective view of Rogowski coil segments mounted on the winding mandrel and wound in accordance with an embodiment of the present invention.
Figure 181 is a perspective view illustrating the completion of wrapping in the initial clip, in accordance with an embodiment of the present invention.
Figure 18J is a cross-sectional view illustrating shield layer windings on a first Rogowski coil segment, in accordance with an embodiment of the present invention.
Figure 18K is a perspective view of Rogowski coil segments mounted on the winding mandrel and wound with the shield layer, in accordance with an embodiment of the present invention.
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Figure 18L is a perspective view illustrating the winding of a layer of tape over the winding shield layer, in accordance with an embodiment of the present invention.
Figure 18M is a perspective view illustrating the completion of windings in the final clip, in accordance with an embodiment of the present invention.
Figure 18N is a perspective view illustrating the insertion of the return conductor, in accordance with an embodiment of the present invention.
Fig. 180 is a perspective view illustrating the insertion of the finishing yarn conductor, in accordance with an embodiment of the present invention.
Fig. 18P is a top elevation view illustrating the insertion of Rogowski coil segments into the head, according to one. embodiment of the present invention. Figure 18Q is a perspective view illustrating the installation of wire conductors in the Rogowski head, in accordance with an embodiment of the present invention.
Figure 18R is a perspective view illustrating the deposit of epoxy on the top head of the Rogowski device, in accordance with an embodiment of the present invention.
Figure 188 is a perspective view illustrating the Rogowski coil device manufactured using the process illustrated in Figures 18A-18R.
Figure 19A is a perspective view of a surface-mountable coil element for use in a Rogowski coil device, in accordance with an embodiment of the present invention.
Figure 19B is a top view of an exemplary Rogowski coil device utilizing the surface mountable coil elements of Figure 19A.
Figure 19C is a perspective view of the Rogowski coil device illustrated in Figure 19B.
Figure 20A is a perspective view of the coil assembly | surface mountable, in accordance with another embodiment of the present invention.
Figure 20B is a perspective view of the surface mountable coil assembly of Figure 20A, showing the hinged nature of the individual coil elements.
Figure 21 is a perspective view of a Rogowski coil device utilizing two substrates and the surface mountable coil elements of Figure 19A.
Figure 22 is a perspective view of an articulated double spool assembly in accordance with an embodiment of the present invention.
Figure 23A is an end view of a first embodiment of a zigzag coil arrangement arranged around a busbar in accordance with the principles of the present invention.
Figure 23B is an end view of a second embodiment of a zigzag coil arrangement disposed around a collector bar in accordance with an embodiment of the present invention.
Figure 24 is a top view of a closed loop, zigzag spiral Rogowski coil device in accordance with an embodiment of the present invention.
Figure 25A is a top view of a first embodiment of an unclosed loop sensor and spiral arrangement in accordance with an embodiment of the present invention.
Figure 25B is a top view of a second embodiment of an unclosed loop sensor and spiral arrangement, in accordance with an embodiment of the present invention.
Figure 26 is a perspective view of a Rogowski coil device with an integrated collector bar, in accordance with an embodiment of the present invention.
Figure 27A is a perspective view of a surface-mountable Rogowski coil device in accordance with an embodiment of the present invention.
Figure 27B is a perspective view of the bobbin device. Surface-mountable Rogowski's in Fig. 27A mounted on a substrate.
Figure 28 is a top view of a multiple sensor module with built-in crosstalk compensation, in accordance with an embodiment of the present invention.
Figure 29A is a process flow diagram illustrating a first exemplary Rogowski coil device winding technique with the lead outs positioned in a center spiral, in accordance with an embodiment of the present invention.
Figure 30 is a front view of a seat winding configuration in accordance with an embodiment of the present invention.
Figure 31 is a process flow diagram illustrating an alternate direction shield winding in accordance with the principles of . present invention. Figure 32 is a cross-sectional view illustrating interleaved shielded windings disposed on the first Rogowski coil segment, in accordance with an embodiment of the present invention.
Figure 33 is a top view illustrating the shielding of individual spiral segments, in accordance with an embodiment of the present invention.
Figure 34 is a top view illustrating the inner diameter shielding of a current sensor in accordance with an embodiment of the present invention.
Figure 35A is a perspective view of a first embodiment of a circuit panel mounted, multi-coil current sensing apparatus in accordance with an embodiment of the present invention.
Figure 35B is a perspective view of a second embodiment of a circuit board mounted multi-coil current sensing apparatus in accordance with one embodiment of the present invention. Figure 35C is a flowchart illustrating an alternative winding configuration. for the multi-coil current sensor apparatus of figures 35A or 35B.
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All figures shown here are Copyright 2009-2010 Pulse Engineering, Inc. All rights reserved. Detailed Description of the Preferred Embodiment Reference is now made to the drawings in which like numerals refer to like parts.
As used herein, the terms "spiral" and "shape" (or "former") are used without limitation to refer to any structure or component(s) disposed on or within or as part of an inductive device. , which helps form or maintain one or more device windings.
As used herein, the terms "electrical component" and "electronic component" are used interchangeably and refer to components adapted to provide some electrical and/or signal conditioning function, including, without limitation, inductive ballasts. ("reactance coils"), transformers, filters, transistors, spaced apart core toroids, inductors (coupled or otherwise), capacitors, resistors, operational amplifiers and diodes, which distinct components or integrated circuits , either alone or in combination.
As used herein, the term "inductive device" refers to any device using or implementing induction, including, without limitation, inductors, transformers, and inductive reactors (or "reactance coils").
As used herein, the terms "network" and "carrier network" refer generally to any type of data, telecommunications or other network, including, without limitation, data networks (including MANs, PANs , WANs, LANs, WLANs, micronets, piconets, internets and intranets), fiber coaxial hybrid networks, satellite networks, cellular networks and telecommunications networks. These networks or portions thereof may use any one or more different typologies (eg, ring, bar, star, loop, etc.), transmission media (eg, RF cable/cable, RF wireless, millimeter waves , optical, etc.) and&/or communications or network protocols (eg SONET, DOCSIS, IEEE Std. 802.3, 802.11, ATM, X.25, Frame Relay, 3GPP, 3GPP2, WAP, SIP, UDP, FTP, RTP /RTCP, H.323, etc). Ethernet (eg 10/100, 10/100/1000 (Gigabit Ethernet), 10-Gig-E, | etc.), MoCA, optics (eg PON, DWDM, etc.), Serial ATA (eg, SATA, e-SATA, SATAII), Ultra-ATA/DMA, Coaxsys (eg, TVnet'”), radio frequency tuner (eg in-band or OOB, cable modem, etc.) , WiFi (802.11a,b,g,n), WiMAX (802.16), PAN (802.15), IrDA, or other wireless families.
As used herein, the term "signal conditioning" or "conditioning" will be understood to include, but not so limited to, signal voltage transformation, noise filtering and mitigation, signal splitting, impedance control and correction, current limiting, capacitance control and time delay; As used herein, the terms "top", "bottom", "side", "up", "down" and the like only imply a position or geo - relative metrics from one component to another and in no way imply . an absolute frame of reference or any required orientation. For example, a "top" portion of a component may actually reside 'below a "bottom portion ", when the component is mounted on another device (eg on the underside of a PCB).
As used herein, the term "wireless" means any wireless signal, data, communication or other interface, including without limitation, Wi-Fi, Bluetooth, 3G (eg, 3GPP, 3GPP2 and UMTS), HSDPA/HSUPA, TDMA , CDMA (eg I1S-95A, WCDMA, etc.), FHSS, DSSS, GSM, PAN/802.15, WiMAX (802.16), 802.20, narrowband/FDMA, OFDM, PCS/DCS, analog cellular, CDPD, systems satellite, millimeter wave or microwave, optical, acoustic and infrared (ie DA) systems.
Overview The present invention provides, inter alia, improved low cost current sensing apparatus and methods for manufacturing and using the same. In one embodiment, the current sensing apparatus are formed into segments which are, in exemplary embodiments, generally linear in nature so as to facilitate the winding of the apparatus. The formed segments are subsequently positioned in geome- | complex tris such as circular, polygonal or elliptical torus/toroidal-like geometries. Although torus geometries are common, the formed segments can be adapted for use with a wide variety of geometries, where the conductors around which they are formed are irregular in nature. In addition to the substantially fixed shapes, additional embodiments disclosed herein are also suitable for flexible assemblies.
The aforementioned "segmented" coil approach advantageously allows the device's manufacturing cost control to be balanced against the required performance or level of accuracy. As more precision is required for a given application, a greater number of segments (and/or greater number of turns per segment) can be used, which also corresponds, in general, to a higher manufacturing cost. In low precision applications, a lower precision device with fewer segments and/or turns can be used, thus providing the lowest possible cost for the required level of precision.
In an exemplary implementation, the segments are formed from spiral elements with features and/or geometries that advantageously facilitate their assembly in the final complete current sensing apparatus. These spiral elements include one or more articulated couplings, alignment features, molded flexible mesh, etc. in order to facilitate assembly. In an alternative embodiment, the segments are formed from self-supporting bonded wire windings, which are subsequently placed in a protective head element. One or more return or pass-through conductors are also used, which are electrically coupled to the windings to form the current sensing apparatus.
In addition, some embodiments disclosed herein include an insert molded or post-inserted conductive clip, which can be used not only for wire wrapping (i.e., to secure the windings before being wound onto the spiral elements) but also for electrically coupling conductor wires to the element windings | coil connections, thus facilitating the electrical connections necessary to form a Rogowski coil device. Lugs formed on the outer flanges of spiral elements are also disclosed for use in some embodiments. These bosses are included as matched paired holes to provide alignment and stability during winding operations.
In exemplary embodiments of the device, the head and/or spiral elements are formed with features that are advantageously incorporated into the device's geometry in order to support and precisely position the return conductor(s) with respect to the windings in the device. The positioning of the return conductor can be balanced against performance considerations and manufacturing considerations in order to provide a high-degree current sensing apparatus; performance and low cost. The position of the conductor can even be variable in nature, for example, through a structure that supports i multiple different positions of the conductor(s).
"Free space" or "formless" modalities of the device are also disclosed in which the turns of the winding(s) (and the segments themselves) are formed and used without a spiral or other support structure, In a variant, so-called "bonded" yarn is used in which the individual turns of the winding are selectively bonded together (eg via a thermally activated adhesive or other substance) in order to maintain the turns in a desired position and orientation. in relation to each other, thus eliminating the spiral and reducing the cost of manufacturing. In another variant, the windings (and the center conductor) are encapsulated in a polymer or other encapsulating compound, which "places in a container" the windings and conductor in relative position and add mechanical stability and rigidity.
Self-conducting modalities are also disclosed which utilize, for example, surface and mounting terminations that allow each of the segments to be connected (electrically and mechanically) to an underlying circuit board.
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"Adjustable" modalities are also considered, which place two (2) or more of the aforementioned current sensing devices adjacent to each other in order to correct segment-related electrical performance deficiencies and/or allow for adjustment. selection of coil performance by a user or installer. In one embodiment, two or more spools are arranged in a stacked or juxtaposed orientation and placed relative to one another so as to cancel or mitigate leakage flux associated with clearances between the spool segments.
In another variant, the two or more coils are substantially concentric.
"Open" modalities (ie, those that do not form a closed structure) are also disclosed. In addition, various device packaging options. (such as packaging options that included integrated busbar connections), as well as various winding and shielding configurations that can be used with various modalities of the segmented spiral and spiral assemblies described herein are also described. Detailed Description of Exemplary Embodiments Detailed descriptions of the various embodiments and variants of the apparatus and method of the invention are now provided. Although discussed primarily in the context of current sensing devices, and in particular in a modality for current sensing devices that operate according to the Rigowski principle, the various apparatus and methodologies discussed here are not so limited. In fact, many of the apparatus and methodologies described herein are useful in fabricating any number of complex coil configurations (such as wound log shapes (which can benefit from the segmented fabrication methodologies and apparatus described herein, including devices that do not). use or need a ticket or return conductor.
In addition, it is further appreciated that certain features discussed with respect to specific modalities can, in many cases, be readily adapted for use in one or more other modalities | considered which are described herein.
It will be readily appreciated by one of ordinary skill, given the present description that many of the aspects described here are most useful outside of the specific examples and implementations with which they are described. —Rogowski Coil Principles In order to better understand various design considerations in implementing the methodologies for making exemplary coils, as described hereafter, it is useful to understand the underlying principles that govern the behavior of a Rogowski coil.
As is well understood in electronic techniques, the voltage produced by a Rogowski coil is driven by Equation (1) below: Equation (1) v= —ANyno dr ! dt Where: A = the area of one of the small loops; - N = the number of turns; | = is the length of the winding; Ho = a magnetic constant; and di/dt = is the rate of change of current in the loop.
In order for a real-life implementation to operate closer to the theoretical behavior presented in Equation (1), several assumptions are made including that the turns are evenly spaced and that the radius of the device is comparatively large compared to the radius of the turns themselves.
Consequently, these assumptions and how they affect the sensitivity of the Rogowski coil itself will be kept in mind in the subsequent discussion of various coil devices, as presented below.
Current Sensing Apparatus Referring now to Figures 1-1B, a first embodiment of a current sensing apparatus 100 is shown and described in detail.
Specifically, a current sensing apparatus of the Rogowski type is illustrated in the embodiment of figures 1 - 1B.
Figure 1 illustrates the main elements associated with the current sensing apparatus, including a bo- | coiled bin 102m a passageway or return conductor 104 and a segmented head 110.
As can be seen in Figure 1, a first major advantage of this device 100 over other prior art Rogowski coils is readily evident. Specifically, typical prior art Rogowski coils emphasized an even distribution of the coil windings throughout the device loop, which was widely believed to be necessary in order to obtain adequate electrical performance for the device. However, it has been discovered by the Assignee that this prior art construction is not only difficult to manufacture (resulting in relatively high sales prices for the device), but also not necessary in order to obtain a desired level of electrical performance for the device. Rather, by segmenting the current sensing apparatus 100 into multiple, substantially uniformly wound coil segments 102, the underlying device is not only easier to manufacture, but provides similar or improved electrical performance in compared to traditional Rogowski coil devices. In an exemplary embodiment, the coil segments 102 are wound onto a linear mandrel using a bonded wire winding. In addition, regular insulated wire can also be used in conjunction with a bonding/gluing process. Bonded wire is a well-established product/process that is used to produce so-called "air coils". The air coils themselves are inductors and have conventionally been used in RFID tags, voice coils, sensors and the like. Materials and fabrication equipment for the production of bonded wire are commercially available from a variety of sources known to those of common skill; The bonded wire is essentially a wire coated with an enamel, having additional coating applied (by the wire vendor or device manufacturer) to the external surfaces of the enamel. Generally speaking, during winding, the bonded wire coating can be activated (usually by heat, although other types of processes, including radiation flux, chemical agents and so on) | to make the coated wires stick or bond together. This approach provides certain benefits and cost savings in the context of producing electronic components. Through the use of bonded wire, the coil segment 102 itself becomes a self-supporting structure. The use of bonded wire in general is well known and its use in the construction of inductive devices is described in detail, for example, in co-owned United States Patent Application Serial No. 10/885,868, filed at 6 of July 2004 and entitled "Form-less Electronic Device and Methods of Manufacturing", the contents of which are hereby incorporated by reference in their entirety.
Device 100 of Figure 1 illustrates only a single segment of coil 102 installed in segmented head 110, although it will be appreciated that device 100 is intended to operate with eight (8) segments of coil, as illustrated. Furthermore, although eight (8) segments of coil 15 are shown, it is appreciated that more or fewer segments can be added, depending largely on the overall size of the current sensor apparatus 100 and its desired shape/profile. The ability to modify the number of coil segments provides a distinct competitive advantage over prior art current sensing apparatus manufacturing methods. Specifically, as the number of coil segments increases (ie, it advances towards a theoretical infinite number of segments), the behavior of the current sensing apparatus will tend to perform more like an ideal coil. , however, this comes at the expense of complexity and manufacturing cost. Conversely, however, the number of segments can also be decreased until a minimum acceptable level of electrical performance has been achieved, thus minimizing fabrication complexity as well as fabrication cost.
Referring now to Figures 1A and 1B, the construction of the exemplary embodiment of the segmented head 110 is more easily seen. The segmented head 110, in the illustrated embodiment, comprises eight (8) cavities 112, each associated with individual ones | of the spool segments 102. Preferably, the segmented head 110 is constructed from an injection molded polymeric material, although other materials of construction, including, without limitation, composites, fibrous materials (e.g., paper) and combinations of the foregoing, as well as alternative methodologies (eg, transfer molding or assembly/adhesive processes) are readily apparent to one of ordinary skill given the present description. In exemplary embodiments, multiples of the pass-through conductor retaining features 114 are positioned at multiple points along the segmented head and between adjacent cavities 112 and are used to retain the pass-through conductor (or conductors) 104 (Figure 1) at a desired location with respect to positioned coil segments 102. Retention features 114, in the illustrated embodiment, position the through conductor(s) 104 along the longitudinal axis of each | 15 of the coil segments, although it is recognized that the placement of the conductor(s) passing through can be varied (and, in the case where multiple conductors can be used, they can actually occupy different positions within the segments ). See, for example, the discussion of Figure 7 here, subsequently. In addition, resources 116 provide a place for wrapping interconnecting wires between segments.
Although the current sensing apparatus illustrated in Figures 1 - 1B is specifically adapted for applications where the conductor from which current will ultimately be detected is capable of being passed through the central portion of the apparatus 100, it is recognized that the segment head. can be manufactured so that it is not a uniform static structure. For example, it is recognized that the apparatus 100 could be articulated such that the segmented head 110 is capable of being wrapped around the current carrying conductor for installation purposes or allows for measurement/testing by an operator. / installer in the field. In addition, a segmented articulated head could also be readily adapted so that the flexible nature of the head operates in more than a single rotational degree of freedom. For example, the segmented head | not only could it be adapted to allow the enclosed loop of the device to be opened and closed, but it would also be allowed to articulate and twist so as to facilitate the ability of the segmented head to be accommodated in any number of difficult installation locations in the field.
The opposite end (that is, which is not hinged) could then be further fitted with a retaining mechanism (such as a pressure spring and the like) which retains the hinged apparatus in its closed form. It is further recognized that this can be accomplished without linkages (eg via the use of pegs, pressure springs, through conductor tension, etc.) or via segmentation of the head 110 into two or more portions separable or movable, depending on the needs of the system in which the appliance will finally be installed. The mod- . The separable or movable method of current sensing apparatus 100 described in Figures 1-1B is also recognized as being equally applicable to the other embodiments of current sensing apparatus, described hereinafter.
It should also be noted that the head 110, in certain applications, is readily modified to facilitate mounting of the current sensor apparatus on an external substrate (either via surface mounting or through hole applications). For example, in through-bore applications, the head 110 incorporates openings (not shown) that support and position the ends of conductors used in the current sensing apparatus at a predetermined spacing. These conductors preferably are formed of a conductor wire of sufficient thickness such that deformation of the wire prior to installation is unlikely. In surface mount applications, the head is readily fitted with two or more conductive areas. These conductive areas can be formed from distinct metal plates that are secured to the head or, alternatively, incorporated via any number of well known polymeric plating processes. The ends of the conductors can then be electrically coupled to the conductive areas via welding, resistive welding | va, etc., so as to form an electrical connection between the current sensing apparatus windings and the conductive areas to be mounted on an external substrate via a surface mounting process.
The current sensing apparatus (whether static or otherwise) may also optionally be encapsulated in a shell-type or otherwise encapsulated/molded/overmolded cover, etc., for protection against dust and debris, as well as providing strength accentuated at high voltages, for example, of the conductor being measured by the current sensing device.
Furthermore, it has been found that, in certain implementations, the performance of the current sensing apparatus is extremely sensitive to deformations in the coil segments 102. As a result, by encapsulating the current sensing apparatus in a shell-like cover or otherwise encapsulating the windings, the performance of the current sensing apparatus can be protected | 15 at a relatively cheap cost to the end consumer.
In addition to static modes (ie, where the encapsulated apparatus 100 is substantially rigid, it is recognized that flexible modalities can be readily implemented by using an encapsulation that is flexible.
This flexible device, in an exemplary variant, is formed by the use of a rubber covered shrink tubing disposed around at least portions of the head 110. Referring now to Fig. 1C, an alternative modality of the sensor apparatus of current illustrated in figures 1 — 1B is shown and described in detail.
Specifically, the embodiment of Figure 1C illustrates a continuously constructed helical coil for use with or without a head or spiral element, as illustrated in Figure 1. The current sensing apparatus 180 of Figure 1C is effectively divided into segments 102 via use. of a die of adhesive 120, arranged, for example, on the inner circumference of the coil.
Depending on the particular application, the types of adhesive used can vary widely.
For example, where some flexibility is desired within individual segments 102, a flexible adhesive (such as silicone) is used to allow some movement between individual turns of yarn within a segment 102. Alternatively, where flexibility is not desired , a harder adhesive, such as two-part epoxy, is used to limit the amount of movement between individual turns of yarn within a segment.
In the illustrated embodiment, the current sensing apparatus is formed on a mandrel in a continuous winding. The adhesive is then placed in segmented portions 102 on the inside diameter of the finished current sensing apparatus using a self-dispensing apparatus, thereby substantially automating the fabrication of the current sensing apparatus. Also note that the return conductor (not shown) is routed inside the coil prior to winding. Although the adhesive is primarily envisioned as being placed on the inside diameter of the finished current sensing apparatus, it is recognized that alternative modalities could readily place the adhesive anywhere on the windings (such as the diameter external) and even at multiple locations in the windings (to increase safety and minimize movement between adjacent windings on any given segment). Furthermore, although the adhesive is primarily envisioned as being disposed on the windings in distinct segments, it is recognized that the die of adhesive placed on the windings can be placed continuously along the length of the windings, especially in cases where the adhesive used cures to a flexible form.
Advantageously, the preceding process also lends itself to parallel mass manufacturing operations. For example, a cured mandrel can be used, with the segments for many coils being formed (and cured, if applicable) on top of it, like the preceding adhesive being applied quickly in a downward motion of the mandrel. The individual spools can then be cut on the mandrel (or after removing the entire mandrel assembly, if desired) and the individual cut spools formed into the desired shape (e.g., substantially circular or polygonal) and finished. Similarly, multiples of these chucks can | be processed in parallel, up to the limitations of the manufacturing equipment. This mass manufacturing provides additional economies of scale over and above those provided by coil design alone. The device of Figure 1C can also be encapsulated within a host compound, if desired (eg, potting compound, silicone, etc.), so that its mechanical rigidity is substantially maintained, at least in the critical dimensions. Specifically, it has been recognized by the inventor(s) that the coils described herein can, in many cases, be sensitive (in terms of degradation in performance) to changes in the area or cross-sectional profile of the turns of each segment. For example, if the coils of the segments in the device of figure 1C are squashed or distorted, the accuracy of the device as a whole can degrade significantly. This dimension is more important - than, for example, maintaining the "circularity" of the device as a whole, as well as maintaining the conductor(s) being monitored within the geometric center of the coil/polygon, the device, advantageously, being largely tolerant of the latter. As a result, mechanical stability of at least the cross-sectional area of the coil turns is an important consideration in many applications. Whether this stability is maintained via the use of a hard or rigid outer "wrap" (eg a box, or alternatively a sleeve or other arrangement that covers the outside of the coil) or via encapsulation or via an internal support, like a spiral or head, it is largely a design choice.
Fig. 1D illustrates a top-down view of a current sensing apparatus 100, as shown, for example, in Fig. 1C, which does not have a head member, as shown in Figs. 1-1B. Specifically, Figure 1D illustrates a first exemplary way of making the current sensing apparatus field-installable around a conductor (without requiring removal of the conductor from the device to which the conductor is attached). The current sensing apparatus, illustrated in Figure 1D, has an overlapping end 185 that can be twist-routed. not a driver. The overlap end can then be secured via an adhesive and similar to the other end of the coil.
In this way, the free ends of the coil device can be routed around the existing conductor installation and the two ends overlapping and secured in place, thus forming an effectively unbroken loop. While it will be appreciated that this "overlay" configuration has less accuracy than a comparable "unbroken" device (eg, one without ends per se, but rather made as a continuous loop), it also provides the capability before mentioned field installation, no disassembly and also very low manufacturing cost (as described in more detail below).
It is noted that although the device of Figure 1D illustrates the two ends of the coil overlap in the vertical plane (i.e., normal to the plane of the figure), the overlap ends may overlap radially while maintaining a vertical profile." plane" (ie, one end being disposed on a smaller radius than the other end).
The two free ends of the device of Figure 1C may be joined using any number of different techniques, including (without limitation): (1) using only the existing stiffness or malleability of the coil device, if applicable, to hold the two ends together. in the desired close relationship (ie, "curving" the device into shape); (2) an adhesive to connect the two ends; (3) a shrink tubing section (eg, shrinks when heated) of the type well known in electrical and environmental sealing techniques; (4) a plastic or other clip: (5) using tape (eg, electrical tape or adhesive; or (6) a molded or formed press-fit assembly arranged at the respective ends. Each of the foregoing (in varying degrees) provides the very low cost benefit, especially when used in conjunction with the cost-effective training techniques for the device itself.
Fig. 1E illustrates an alternative field-installable embodiment of the device, wherein the free ends of the sensing apparatus | current 100 support each other at 190. The mode of figure 1E is anticipated to be higher in cost to manufacture than that shown in figure 1D, but provides better electromagnetic performance (accuracy) than the previous mode illustrated in figure 1C, because largely due to the fact that the supported ends effectively allow the coil to be almost "perfect" in shape and prevent any overlap (which causes magnetic distortions and leakage). The ends of the current sensing apparatus may be supported using any number of mounting techniques including, without limitation: (1) a locating pin coupling; (2) a magnetic coupling; (3) a threaded coupling; (4) a shrink tube coupling; and (5) a snap-pivot type coupling.
Regarding the use of a magnetic coupling, it should be noted that the use of a magnet does not influence a change in the current to be me-. (ie dVdt) and therefore advantageously does not affect the electrical performance capabilities of the device.
The modality of figure 1D is slightly more expensive to manufacture than that of figure 1C (due in large part to the cost of the support requirement for the coupling), still providing
at a greater precision.
It will also be recognized that the embodiments of Figures 1D and 1E can be molded to be flexible in multiple dimensions.
For example, in one variant, the coil ends may be slightly apart (to allow wrapping around an installed conductor or busbar) due to coil flexibility (particularly clearances between the segments) still varied vertically with respect to each other (ie, maintain the same radius, still move relative to each other, as torsional forces are applied to both ex-
tremors). In another variant, only a prescribed portion of the coil (eg a "hinging" region, not shown) is allowed to flex significantly.
This can be accomplished in any number of different ways, such as by using a thinner cover material or real mechanical hinge, in the hinge region, so that it flexes, from | preferably in that region.
Referring now to Figures 2-2C, a second exemplary embodiment of a head- or spiral-based current sensing apparatus 200 is shown and described in detail. Specifically, the current sensing apparatus 200 of Figs. 2 - 2C comprises multiples of the segmented spiral elements 210. Each of these spiral elements 210 is arranged next to the other via an optionally articulated coupling 220. At As an exemplary modality, this articulated coupling 220 includes features (such as pressure spring and the like) that retain adjacent segmented spiral elements so that they remain attached to each other, however, it is recognized that in modes alternatives, the articulated coupling may provide only a hinge, as opposed to a hinge and retention function. . In an alternative embodiment, articulated coupling can be accomplished by molding a thin web of connecting material between adjacent spiral elements 210. This configuration could be made static (such as for use in embodiments where the geometry application is known) or flexible as described previously. The coupling can also be made frangible; that is, separable after a limited number of charge cycles, if desired, in order to facilitate selective separation of components.
Referring now to Figures 2 and 2A, a partial segment of a current sensing apparatus 200 is shown. Specifically, only a forty-five degree (45°) segment of a three hundred and sixty degree (360°) apparatus 200 is illustrated. As a result, as can be seen in the illustrated embodiment, the complete apparatus 200 will consist of eight (8) segmented vent elements 210. Although eight elements are considered, this number is arbitrarily defined by the underlying geometry of the current sensing apparatus application. , as well as defined performance parameters. Therefore, it is readily recognized that more or less elements of different shapes or configurations (also including heterogeneous "mixtures" of two or more different spiral element configurations) could be used in alternative embodiments.
The embodiment illustrated in Figures 2-2C also includes a central passage 230 which is intended to position the pass conductor at a precise location within each of the segmented spiral elements. In the illustrated configuration, the passage is positioned along the longitudinal geometric axis (i.e., the geometric center) of each of the cylindrical spiral elements 210; however, as noted herein, the position of the center conductor(s) may be (i) not symmetrical with respect to the cross section of passage 230 or spiral element; (ii) can be variable or changeable; and/or (iit) may reside in other locations.
Figures 2B and 2C illustrate different perspective views of a single segmented spiral element 210 according to an embodiment. The spiral element 210 is characterized by a winding channel 212 adapted to receive one or more layers of windings, while flanges 218 retain the windings in winding channel 212, resulting in uniform distribution. of the windings within the spiral element 210. Although the winding channel is illustrated with a smooth winding cylinder, it is appreciated that grooves could be formed in the winding cylinder in order to provide additional features for guiding the windings. windings so that they are wound more evenly. Furthermore, the cross section of this "cylinder" need not be symmetrical and/or it may also include segmentation (ie it may include an octagon, ellipse, polygon, etc. in cross section).
Positioned at opposite ends of the flanges are in-line columns 216 positioned above brackets 240. These alignment columns 216 are optional but are used to facilitate individual placement of spiral elements 210 within an encapsulation head (see for (example: Fig. 44, 460, described hereafter). Routing columns 214 are used to facilitate the routing of windings between individual spiral elements 210 during automated winding on a mandrel, as will be discussed more fully hereafter. These routing columns 214 act | as entry/exit points for the wire wound into the winding channel 212.
Recalling the discussion of the articulated coupling 220 with respect to Figure 2A. As can be seen in Figures 2B and 2C, the articulated coupling comprises a protruding portion 222 and a respective receptacle portion 224, which is sized to accommodate the protruding portion of an adjacent spiral element 210. The channel Router 232, optionally, can also be used to route the output wire from the last segment to the return wire inside the coil. Note that in the illustrated embodiment, the articulated coupling 220 does not include elements that allow adjacent elements 210 to remain movably coupled to one another. Rather, the voltage associated with the respective windings and lead-through is actually used to retain the current sensing device in its finished tor-like form. However, it is recognized that alternative embodiments may readily include features that physically couple adjacent elements 210 together, use adhesives or other bonding agents, etc. Referring now to Figures 3 — 3D, yet another modality for a current sensing device of the Rogowski 350 type is illustrated. Figure 3 illustrates a single spiral element 300, of which eight (8) are required (for the illustrated embodiment) in order to create a single current sensing device 350. It is recognized that more or less coil elements, those of heterogeneous configuration, etc. they could be used in alternative modalities, as discussed previously in relation to the other modalities. Unlike the spiral element 210 of figures 2 - 2C, the spiral element 300 of figure 3 does not require a hinged coupling. In fact, the spiral element 300 of Figure 3 is constructed so that they form a torus-like structure of the current sensing device 350 when the spiral elements 300 are placed adjacent to one another. See, for example, Figure 3B, which shows exactly half (ie four (4) spiral elements) of the current sensing device.
350. Each spiral element includes a winding channel 310, which is | defined by respective flange elements 330; These flange elements maintain and define the winding width for the winding channel.
310. The spiral element 300 further comprises routing columns 312 which, again, are utilized from the exit/entry points for the winding as they exit and enter the winding channel.
310. In addition, these entry/exit points can also be used to secure the pass-through or return conductor prior to winding. Optional 314 pass-through conductor routing channels are included adjacent to the 312 routing columns. The 314 routing channels are adapted to accommodate one or more pass-through conductors below the windings placed within the 310 winding channel. , the through conductor, which is routed through channel 315, advantageously helps maintain the structural integrity of the assembled device - 350, when assembled, via voltage applied to the through conductor (shown).
2 In an alternative embodiment, the through conductor may actually be routed through the central cavity 320 (ie, along the inner diameter of the central cavity). In addition, spiral element 300 could be readily adapted for accommodation through a central passage constructed within central cavity 320 (similar to that shown in Fig. 2B, 230). These and other modalities will be readily apparent to one of ordinary skill in the art given the present description.
Figure 3A illustrates a side elevational view of the spiral element 300 shown in Figure 3. Specifically, as can be seen in Figure 3A, despite the curved geometry of the spiral element 300, the central cavity 320 passes in the illustrated embodiment. , in a straight line through the body of the spiral element. This facilitates the automated winding of the spiral element (see eg Figures 3C — 3D) The keyed notch 322 also runs linearly along the inner wall of the central cavity 320, thus providing a feature that can be received into a respective slot (see figure 3D, 362) on a mandrel that per- | Allows the spiral element 300 to be rotated precisely during the winding process.
Figures 3C and 3D illustrate four (4) of these spiral elements 300 mounted on a mandrel 360. Note that since the spiral elements 300 are configured in a linear mode, the automatic winding of the final shape is "torque-like" " is greatly simplified compared to a true torus (circular) shape. Collar 370 is mounted on the end of mandrel 360 and secures the spiral elements to mandrel 360. In the embodiment illustrated in Figures 3 — 3D you can then optionally, be encapsulated in a head or housing, such as, for example, an overlapping shell-type head (not shown) or other wrapping.
Referring now to Figures 4-4B, a fourth exemplary embodiment of a current sensing apparatus 400 is shown and . described in detail.
Specifically, the current sensing apparatus 400 i 15 of Figures 4-4B comprises multiples of the segmented spiral elements 410. outer ring 460 (figure 4A). Figure 4 illustrates a partial segment of the current sensing apparatus 400 of Figure 4A.
Specifically, only a forty-five degree (45º) segment of a three hundred and sixty degree (360º) 400 apparatus is shown.
Accordingly, in the illustrated embodiment, the complete apparatus 400 will consist of the number of cavities 464 in the ring-like heads 460 of Fig. 4A.
The spiral element 410, illustrated in Figure 4, includes a central passage 430 which is designed to position the through conductor at a precise location within each of the segmented spiral elements.
In the illustrated embodiment, the passage is positioned along the longitudinal geometric axis of the cylindrical spiral element 410. The spiral element 410 of Figure 4 also includes an alternative passage 432 that can be used to route the return wire through the center of spiral segment for ease of assembly.
The spiral element 410 is characterized by a winding channel 412 adapted to | receiving one or more layers of windings, while flanges 418 retain the windings in winding channel 412, resulting in an even distribution of the windings within the spiral element
410. Positioned at opposite ends of the flanges are alignment columns 416 positioned above brackets 440. These alignment columns 416 are optional but are used to facilitate individual placement of spiral elements 410 within head 460. Routing features 422 are used to facilitate the routing of the windings between the individual spiral elements 410 during automated winding on a mandrel, as will be discussed more fully hereafter in relation to Figure 4B. These routing features 422 act as input/output points for the wire wound within the winding channel 412.
Figure 4B illustrates individual spiral elements 410 mounted on a mandrel 470 for the purpose of automated winding of 2 individual spiral elements. As can be seen, an s/ot 472 is machined or otherwise formed in the winding mandrel 470. This slot 472 is sized to accommodate a respective feature 434 (figure 4) in the individual spiral elements, which facilitates the operation of winding. A collar 480 is placed through one end of the mandrel 470 to hold and position the individual spiral elements 410 in a secure location along the axis of the mandrel. This approach allows for repeatability and consistency during the winding process, without the need for vision equipment, to help locate the feed end of the automated winder.
Note also that all eight (8) segments 410 used to form the current sensing apparatus are arranged in a single winding mandrel 470. Although previous embodiments (figure 3C) have illustrated only a portion of the entire sensing apparatus being formed at any time on a mandrel, the embodiment of Figure 4B illustrates an embodiment in which all segments can be wound in a single winding operation. The wrapped segments can then be | subsequently removed from the mandrel and placed in the heads 460, as shown in figure 4A.
Referring now to Figures 5-5C, yet another embodiment of a spiral element 510 for use in a current sensing device is shown and described in detail. The spiral element shown in Figure 5 is similar in construction to the articulated mode shown previously in Figures 2-2C. Specifically, the embodiment illustrated in Figure 5 is similar in that it has a winding channel 512 defined by outer winding flanges 518. In addition, the illustrated embodiment further includes routing columns 514 to facilitate routing of magnetic wire between adjacent winding channels (see figure 5C). The hinge element 522 is also adapted for receiving in a respective feature located in an adjacent spiral element 510: and acts as a pivot point for the spiral elements, similar in functionality as described with respect to figures 2 — 2C. See also pivot point 550 shown in figure 5B. Furthermore, the collective spiral elements can then optionally be placed within a shell-like cover (not shown) or other encapsulation or between a pair of head elements (similar to those shown in Figure 4A,460).
However, unlike the previous embodiments discussed, the embodiment of the spiral element 510 illustrated in Figure 5 differs in that the through or return conductor(s) (not shown) are not routed through the central opening 534 , as illustrated in the previous embodiment of figures 2-2C, above, the wire routing opening 530 is used for this purpose. The wire routing opening 530 is positioned within the body of the winding cylinder, the outside diameter of which defines the winding channel 512. This configuration has mounting advantages as the through conductor is resident in the diameter. internal of the finished current sensing device. As the through conductor is on the inside diameter, the length of the through conductor, advantageously, does not need to be significantly elongated, | as the individual spiral elements 510 are formed in their final torus shape.
This allows, inter alia, greater simplicity and efficiency in manufacturing.
In addition, as the through conductor is not positioned within the central opening 534, it can be easily accommodated during the mandrel winding process with the individual spiral elements 51- each mounted in the chuck 560. Also note that the flat surface 536 (as perhaps best shown in figure 5A) corresponds with a flat surface 570 located on the chuck 560. This geometry helps ensure that the spiral elements 510 rotate with the chuck rotations .
Figures 6-6B illustrate another variant of the current sensing apparatus of Figures 5-5C.
The mode of figures 6-6B is similar by . fact that it is composed of 610 spiral elements for use in a current sensing device.
The spiral element 810 comprises a hinged assembly similar to that illustrated in Figures 2-2C.
The spiral element further has a winding channel 612 defined by the outer winding flanges 619 and further includes routing columns 614 to facilitate the routing of magnetic wire between adjacent winding channels (see figure 6B ). The hinge element 622 is also adapted for receiving in a respective feature, located in an adjacent spiral element 610 and acts as a pivot point for the spiral elements, similar in functionality as described with respect to figures 2 — 2C and Figures 5-5C.
See also pivot point 650 illustrated in figure 6B.
The collective spiral elements 610 can then optionally be placed within a shell-like cover (not shown) or other wrapping or between a pair of head elements (similar to that shown in figure 44, 460 ). The embodiment of the spiral element 610 illustrated in Fig. 6 differs from the above illustrated embodiments in one important respect, namely, that the routing channel (not shown) is not routed through the center opening as illustrated in the previous embodiments.
Before, the s/ot of | 630 wire routing is used for this purpose. Wire routing s/ot 630 is positioned on the outer periphery or outer diameter of the winding channel. This configuration has mounting advantages, as the return conductor is resident not only in the inside diameter of the finished current sensing device, but also does not need to be threaded through an opening, thus simplifying mounting.
It should also be noted that the routing slot can be used to operate the return wire (conductor) and/or a flexible cable recess (non-conductor). For example, in a variant (see figure 6C),. The wire being wound around the coils would capture and secure the cable (not shown) above mentioned in the outer slot 631 to the individual coil elements so as to provide a flexible articulation between them and add mechanical stability (as well as protect the wire from crossover during assembly). This cable does not have to be round in cross-section, in fact, it can literally have any cross-sectional shape, including, without limitation, square, rectangular, polygonal, oval/elliptical or even be a composite of multiples. wires (eg braided).
Furthermore, because the return conductor is in the inner diameter, the length of the return conductor does not need to be significantly elongated, as the individual spiral elements 610 are formed in their torus shape, as previously discussed. Furthermore, as the return conductor is not positioned within the central opening 634, it can be easily accommodated during the mandrel winding process. With the individual spiral elements 610 each assembled, the nomandril 560 shown in Figure 5C.
Referring to Figure 7, several exemplary positions for a return or return conductor in a spiral element 700 are shown. Specifically, Figure 7 illustrates various options for positioning the return conductor with respect to the spiral element 700 and the respective windings 710 disposed on that element. While simultaneously illustrating multiple return conductors (720, 730, 740, 750, 760) it is recognized that in most modalities, only one |
Only position for return conductor will exist at a time. The various options illustrated are as follows (these are not intended to be limiting and there are other options): Option (1) - The return conductor 720 can be placed within the radius of the inner diameter of the 700 spiral element, similar to positioning, as shown in the embodiment of Figures 5-5C; Option (2) — The 730 return conductor can also be placed external to the 710 windings. Although unconventional, this arrangement has been found to be effective as long as the 730 return conductor is in physical contact with the 710 windings. It is appreciated that the return conductor 730 literally can be placed anywhere along the outer periphery of the windings 710; Option (3) — Through conductor 740 can be placed at the geometric center of spiral element 700 (ie, along the geometric longitudinal axis of the winding), as shown, for example, O in figures 2-2C; Option (4) - The through conductor 750 can be positioned along the radius of the outer diameter of the spiral element 700 internal to the windings 710; and/or Option (5) - The 760 through conductor may be positioned out of plane with respect to the positions of the inner conductor 720 and the outer conductor 750, as shown in (1) and (4) above.
The various options discussed above with respect to Figure 7 have various tradeoffs between electrical performance versus manufacturing capability.
For example, in some applications, the degradation in electrical performance seen by a current sensing device is not significant enough to offset the ease of fabrication benefits by placing the feedthrough conductor closer to the inside diameter of the power supply. completed current sensing apparatus (as discussed above with respect to, for example, Figures 5-5C). Alternatively, in high performance and/or precision application, the additional manufacturing cost can be justified by the high level of performance/precision. These | exchanges will be readily understood by one of common ability given the present description and, consequently, are not discussed here.
Referring now to Figure 8, yet another embodiment of a current sensing apparatus 810 is shown and described in detail. Specifically, the embodiment of Fig. 8 addresses the special case where the current-carrying conductor 820 to be detected is oblong or otherwise irregular in shape. This oblong shape, as illustrated, is common, for example, in many power company applications (such as, for example, in so-called collector bars, used in power distribution boards, distribution stations and distribution substations).
As discussed previously, the current sensing apparatus of prior embodiments was primarily considered to be generally tor-like in shape as is conventional in the prior art.
However, it has been found that by stretching the current sensing apparatus 810 so that it now comprises a generally oval or elliptical-type shape to accommodate the oblong shape of conductor 820, improved electrical performance is obtained. Remember from the above that the voltage sensitivity of a Rogowski coil is driven by equation (1), where: Equation (1) v= —ANuç dl 1 dt Consequently, because it has a general form of type oval, the current sensing apparatus has a relatively shorter length (than a prior art round Rogowski coil), thus increasing the voltage level seen in the current-carrying conductor 820. In addition to the curved configurations, too it is recognized that square and rectangular configurations can be used equally.
In embodiments utilizing the segmented spiral elements (eg segmented spiral element 210, figure 2) or alternatively the head element (110, figure 1), it is appreciated that the central opening 830 it can be sized to accommodate conductor 820 without having to physically vary the shape of the segmented windings themselves. In other words, the spiral element or the | head is physically sized to accommodate the conductor. Figure 8a illustrates this example implementation. Specifically, Figure 8A illustrates a current sensing apparatus 850 formed from a plurality of segmented spiral elements 852, each having a number of conductive windings 854 wound thereon. These segmented spiral elements are then used in conjunction with alignment elements 856 in order to align the spiral elements around the conductor 820 to be measured. In this way, the alignment elements prevent tilting of the current sensing device 850 when placed around the conductor and still provide accurate and repeatable placement (ensuring consistent electrical performance for field-installed current sensing device).
Furthermore, in other embodiments, the alignment elements are interchangeable, such as to accommodate bus bars of different shapes and sizes and/or the placement of the conductor within different E portions of the central opening of the coil. Similarly, for the free space or shaperless arrangements, described elsewhere here, a central alignment element can be used which positively places (and orients) the sensor apparatus around the conductor.
Figures 8A and 8B-1 illustrate yet another embodiment of the search coil of the invention, realized in a substantially rectangular form factor, having four (4) (or multiples of 2) segments corresponding to each of the four sides of a conductor. rectangular. As shown in Figure 8B, the four segments 870, 872, 874, 876 are disposed at 90 degrees to each other, corresponding to the four sides of the collector bar 878. The side coil segments 872, 876 are longer in length ( and have more turns) than coil end segments 870, 874, although it will be appreciated that other configurations can be used (including four identical segments, segments of the same length but of different turn density, segments of different lengths , but with the same density back and so on). In addition, the configuration in figure 8B can be used with conduit | square conductors (not shown) or multiple conductors whose composite sketch forms an effective rectangle or square.
Device 868 of Figures 8B and 8B-1 is, in illustrated embodiment, disposed within a hard shell or box 880 (shown with part of the box "shell" removed in Figure 8B), though other approaches (including (for example, encapsulation, or use of a head or spiral for support) can be used, as well.
Figure 9 illustrates an alternative to the substantially round winding channels 910 associated with typical prior art current sensing apparatus.
As can be seen in Figure 9, the cross-sectional length of the current sensing apparatus 920 has been extended along the path of conductor 940 in which current is desired to be detected. placed within the 920 current sensing apparatus in any number of locations, considering the various design changes, as presented in the discussion of figure 7 above.
Consequently, as the cross-sectional area (A) has been increased (as shown in Equation (1) above), the measurement of the voltage level of the current-carrying conductor 940 increases.
Although Rogowski-type coils have typically maintained their traditionally circular and tor-shaped shapes due to a fear that deviation from these shapes would adversely affect the electrical performance of the coil, it has been found that in many applications, these deviations are acceptable in implementation.
In yet another embodiment of the invention, two or more "layers" of windings can be used to form the coil and return conductor.
For example, in one variant, a first layer of bearings is applied across the top of the spiral or head segments in order to effectively provide complete coverage of the spiral segment or head elements.
At the end of the first layer, the same winding is "folded back" over itself and over the top of the first layer to form a second layer.
The first layer actually acts as a return conductor within the second layer, | although the return conductor layer need not necessarily be the first layer. It will be appreciated that more layers for the (second) return and/or "top" layer can be used if desired. In addition, winding densities and topologies can be varied for each layer, such as, for example, where the return conductor layer is wound at a lower density (greater inter-turn spacing) than the top layer. It will be appreciated that the "layered" approach mentioned above does not need to be used in conjunction with the spiral or head, at all. For example, in a "free standing" variant, bonded wire of the type discussed previously is used to form the first and subsequent layers (eg, wound on top of a mandrel or other removable structure and then bonded together. and the mandrel/frame removed). Alternatively, unalloyed wire can be used and subsequently encapsulated or held in place with adhesive prior to removal from the mandrel! Support. o A myriad of other variations will be appreciated by those of common ability given the present description. Referring now to Figures 16-16D another exemplary embodiment of a head- or spiral-based current sensing apparatus 1600 is shown and described in detail. Similar to the other embodiments disclosed, the current sensing apparatus 1600 of Figures 16 - 16D comprises multiples of the segmented spiral elements 1610. Figure 16 illustrates a single of the segmented spiral elements 1610 in detail, such as the spiral element illustrated 1610, adapted for coupling to another segmented spiral element via a hinged coupling.
1620. Other coupling types may be used consistent with this modality. In the illustrated embodiment, this articulated coupling 1620 includes a pair of hinge features 1621, 1623, with a through hole 1632 disposed in each such feature that is sized to accommodate an inserted pin (item 1650, Figure 16A). The articulated coupling in combination with the inserted pin is somewhat similar to what is seen | on a typical door hinge. These swivel couplings include a pair of outer swivel couplings 1623 and a pair of inner swivel couplings 1621, which are designed to retain adjacent segmented spiral elements. Specifically, the pair of outer swivel couplings 1623 is spaced a distance apart that a respective pair of inner swivel couplings 1621 can fit between them. It will be recognized that each segment element 1610 (i.e., each side or interface portion) may include (i) the pair of outer hinges; (ii) the pair of internal joints; or (ilijuma mixture of the foregoing. In one variant, the segment elements are each made identical to one another for ease of assembly and lower cost, although this is not a requirement. In addition, the segment elements they can have at least two-dimensional symmetry so that they can be inserted into the assembly in two different orientations, thus simplifying assembly from the point of view that an automated or manual assembly process does not have to orient the part correctly in all directions. three dimensions for mounting (rather than just with respect to two dimensions). Each of the pairs of swivel couplings illustrated in figure 16 also incorporates a chamfered entry for the through hole
1632. This beveled entry makes it easy to insert the inserted pin for easy assembly. In addition, and similar to the other embodiments of spirals illustrated previously discussed herein, the spiral element 1610 of Figure 16 also includes a winding channel 1612 with flanges 1618 disposed on either side of the winding channel. The winding channel is further defined by a spool or cylinder 16813, which provides radial mechanical support for the insulated windings. The spiral element also includes a return conductor passage 1630 positioned within a return conductor alignment feature 1634. The return conductor passage 1630 is intended to position the pass conductor at a precise location within | each of the segmented spiral elements.
In the illustrated configuration, the passage is positioned along the longitudinal axis (i.e., the geometric center) of each of the cylindrical spiral elements 1610; however, as noted herein, the position of the center conductor(s) may be (1) not symmetrical with respect to the cross-section of passageway 1630 or spiral element (ii) may be variable or interchangeable; and/or (ii)
may reside in other locations.
Figure 16 also illustrates some additional features not present in some of the other illustrated spiral element modalities, although it is recognized that these and other illustrated modalities could readily incorporate these features.
These features include 1638 winding alignment bosses along with associated 1636 alignment holes.
These lugs and holes are useful during the E. winding process to ensure that proper alignment is maintained between adjacent spiral elements 1610 (i.e., preventing relative twisting oC when the wire is being wound on a winding mandrel, etc.). ) and maintain stability when spiral elements are rotated at high speed.
1616 lead clip openings are also included in the illustrated flange embodiment.
These openings 1616 are sized to accommodate a respective clip (not shown), which is then used to facilitate the connection of resident windings with winding channel 1612 to the return conductor and to an external connection (see, for eg the discussion of fabrication in relation to, inter alia, figures 18A-188). Note that the illustrated embodiment of the spiral element 1610—1 includes (2) substantially identical clip openings 1616 located on opposing flanges 1618. However, alternative embodiments could utilize "keyed" clip openings that differ in such a way as - plo, prevent insertion of improper clips (ie where the clips differ between the "start" and "end" winding ends of the Rogowski coil device.
Furthermore, although illustrated as a so-called post-inserted configuration, it is recognized that the lead clip could also be motl- | given by insertion into the flange (ie during injection molding of the spiral element itself), thereby securing the clip to the spiral element. Still other techniques recognized by those of common skill given the present description may be used, as well.
Figure 16A illustrates the total or collective number of spiral elements 1610 in a single device 1600, coupled together via their respective hinge coupling pins 1650. Also note that windings 1660 have now been added to each of the spiral elements , as shown in Figure 16A. As previously discussed herein, spiral element 1610 is characterized by a winding channel adapted to receive one or more layers of windings, while flanges retain the windings in the winding channel, resulting in at least a substantially uniform distribution of the windings. - threads within each of the spiral elements 1610. Although the winding channel is illustrated with a smooth winding roller or spool, it is appreciated that grooves could be formed in the winding roller in order to provide a means to guide the windings during the winding process so that they are wound more evenly. Furthermore, although illustrated as a symmetrical and circular cylinder, it is recognized that the cross section of this "cylinder" need not be symmetrical and/ or it may also include segmentation (i.e. it may comprise an octagon, an ellipse, a polygon, etc., in cross section), as discussed here p. again.
Figure 16B illustrates an exploded view of the Rogowski coil device 1600 when each of the spiral elements is close to being mounted within a housing. Housing in this embodiment is comprised of a top 1670 and bottom 1680 housing cover, although other configurations may be used.
Figures 8C - 16D illustrate how each of the spiral elements 1610 is supported within the housing. As can be seen in figure 16D, the bottom housing cover 1680 includes a number of features that facilitate mounting the device. More specifically, these | features aid in the precise placement of the 1610 spiral elements within the housing.
1684 Hinge Pin Receptacles features are adapted to accommodate the 1650 hinge pins present in the 1610 spiral element assembled grouping. These features help ensure that each of the 1610 spiral elements is precisely spaced in order to ensure repeatable electrical performance of the underlying 1600 Rogowski coil device and also aid in the assembly process by registering the various core components in a desired location, Flange Support Features 1682, 1686 as well—are sized to accommodate the shape of the elements of spiral and ensure that they are properly supported within the bottom housing 1680. The bottom al 1680. The bottom housing also includes a center opening 1688 that is designed to accommodate the conductor(s) to be used as measured by the Rogowski coil device 1600. As previously noted, this central opening may be (i) in a shape other than circular and/or not. the symmetrical; and/or (ii) made replaceable to accommodate different cross-sections of conductors (eg, round, tiled, rectangular "bar", etc.)
Referring now to Figs. 17-17C, yet another exemplary implementation of a head-based or spiral-based current sensing apparatus 1700 is shown and described in detail.
This modality incorporates a so-called "active hinge design, con-
as described in more detail below.
Figure 17 illustrates a singular segmented spiral element 1710, which, in combination with other spiral elements (e.g., six(s) in the illustrated embodiment) forms the Rogowski coil device 1700 illustrated in Figure 17A.
Similar to the previous embodiments discussed here, the spiral segments illustrated in Figures 17-17C are each arranged next to one another in a common plane via an articulated coupling 1720. In the illustrated embodiment, however, this articulated coupling. The 1720 side includes a 1725 flexible hinge feature that connects the 1718 flange of the spiral element with an integral coupling portion.
| that of a winding spool portion 1721 together with an insertable portion 1723, the latter sized to fit within an associated opening 1722 located in the winding channel 1712 of an adjacent spiral element. The winding spool portion 1721 includes a curved surface that is molded to have a diameter substantially identical to the underlying winding spool. Furthermore, the thickness of the winding spool portion of the articulated coupling is approximately the same as the depth of the spool cavity 1727, so that when the articulated coupling is coupled to an adjacent spiral element, the coupling provides an almost seam-like fit.
Similar to the other illustrated spiral modalities discussed previously herein, the spiral element 1710 of Figure 17 includes a 2nd winding channel 1712 defined by a cylinder or spool 1713 and flanges 1718 disposed on either side of the winding channel to define a the winding "window" for the spiral. In addition, the spiral element includes a return conductor passage 1730 positioned within a return conductor alignment feature 1734. The return conductor passage 1730 positions the pass conductor at a precise location within each. of segmented spiral elements, as discussed previously. In the illustrated configuration, the passage is positioned along the longitudinal axis (ie, the geometric center) of each of the cylindrical spiral elements 1619, however, as noted elsewhere herein, the position of the conductor(s) Switches can be located in a variety of different locations while still providing adequate electrical performance in most current sensing applications. Figure 17 also illustrates the use of winding alignment bosses 1738 along with associated alignment holes 1736. These lugs and holes are useful during the winding process to ensure proper alignment and stability are maintained between adjacent spiral elements 1710 (ie to prevent relative twisting when the | wire is being wound onto a winding mandrel, etc;) In addition, 1716 conductive clip openings are included in the flange. These 1716 openings are sized to accommodate a respective clip (not shown), which is then used to facilitate the connection of the resident windings with the 1772 winding channel with the return conductor and with an external connection (see, for example, the discussion of fabrication with regard, inter alia, to figures 18A — 18S). Note that the illustrated embodiment of the spiral element 1710 includes two (2) substantially identical clip openings 1716 located on opposing flanges 1718. Furthermore, although illustrated as a post-inserted clip design, insert molding or other techniques they could be readily substitutes as well.
Figure 17B illustrates a cross-sectional view of the Rogowski coil device 1700 of Figure 17A, taken along line: 17B - 17B. The cross-sectional view of Figure 17B helps to illustrate the engagement of various elements of the articulated coupling. Specifically, it shows the insertable portion 1723 of the swivel coupling pushed against the winding spool opening 1722 so as to prevent over-insertion when coupling the various spiral elements. Also, as seen in Fig. 17B, the outer surfaces 1731 of the return conductor alignment feature 1734 are disposed offset (i.e., inwardly) from the outer surface 1719 of the spiral element.
1710. This offset allows for the insertion and alignment of, for example, initials and ends clips 1890, 1892, in figures 18A and 18B, respectively).
Referring now to figures 19A-19C, another embodiment of individualized spiral elements 1900 is shown and described in detail. Each of these spiral elements includes a winding channel 1920 together with respective flanges 1910 disposed at both ends of the winding channel. However, unlike many of the other embodiments disclosed herein, the illustrated spiral element of Figure 19A does not include any kind of an articulated coupling. In other words, 1900 spiral elements are designed to be position- | on a substrate, for example, without requiring them to physically couple with an adjacent spiral element. Removal of an articulated coupling allows individualization of each of the spiral elements, which inter alia adds flexibility to how each of the spiral elements is finally positioned relative to the other spiral elements disposed adjacently within. of a complete inductor device, such as the exemplary Rogowski coil-type devices discussed herein. The spiral element of Figure 19A includes a number of self-conducting terminals 1912 positioned on the sidewall 1924 of the flange.
1910. The self-conducting terminals are arranged so that when the 1922 windings are wound around the terminals, these windings will protrude beyond an upper (or lower) surface 1914 deoo as these windings are subsequently secured. to the terminal, via, for example, a eutectic solder or the like. Exemplary modalities using self-conducting terminals in other applications are discussed in co-owned U.S. Patent No. 5,212,345, filed January 24, 1992 and entitled "Self-leaded surface mounted coplanar header", the contents of which are incorporated herein through reference in its entirety. These self-conducting terminals allow the spiral element to be mounted, for example, on a printed circuit board via conventional processing techniques such as an infrared (IR) reflow solder process. Self-conducting terminals include their own and respective 1916 flanges to retain the 1922 windings and, in the illustrated embodiment, also include a generally triangular winding cross section, though other cross sectional shapes (eg, round, oval, polygonal, etc. .) could be readily adapted to the illustrated spiral element. In addition, the 1910 flanges include a number of 1918 routing features, which help to position and maintain the windings that are routed from the winding channel to the self-conducting terminals. Although the embodiment illustrated in Figure 19A includes terminals | Self-conducting terminals that are formed simultaneously with the spiral elements themselves, using a high-temperature polymer that can withstand temperatures experienced in conventional welding processes, it is appreciated that these self-conducting terminals could be readily replaced by terminals. metals that are insert molded or post-inserted into the spiral element. These metal terminals could be inserted into the sidewall 1924 of the flange or, alternatively, they could be inserted into the bottom (or top) surface 1914 of the spiral element, which is useful, for example, when inserting wires. electrical conductors in the spiral element.
Referring now to Figures 19A and 19C, an individualized spiral element assembly 1950 is shown and described in detail. Specifically, six (6) 1900 spiral elements are shown mounted on a substrate in a generally circular pattern around a 1960 hole located in the substrate, although it is recognized that other numbers and configurations of spiral elements may be used consistently. with the invention. This hole is intended to accommodate the conductor that is to be measured by the 1950 assembly. Figure 19C illustrates another feature of the illustrated mode with respect to the way in which self-conducting terminals 1912 are arranged. Specifically, self-conducting terminals are arranged in this mode in a mode staggered, so that the inner ends 1930 (i.e. on ends more closely positioned towards the center of the substrate) do not interfere with the inner ends 1932 of an adjacent spiral element. An advantage of this staggered design feature is that the spiral elements can be positioned closer together, thus improving the electrical performance of the 1950 assembly as well as, or alternatively, reducing the overall space of the assembly. As is perhaps best seen in Figure 19C, the self-conducting terminals are staggered into both the lower terminals (which interface with the 1970 substrate) as well as the Upper terminals, which, in the illustrated embodiment, do not interface with a substrate.
Referring now to Figure 20A, an embodiment of a | 2050 self-driven articulated spiral element assembly is shown and described in detail. The self-conducting spiral element assembly 2050 is similar in construction to the individualized spiral elements discussed here previously with respect to figures 19A-19C, except that the spiral elements 2000 in figure 20A include a swivel coupling.
2030. Furthermore, although the spiral elements in Fig. 19A are each individually wound and terminated, the embodiment shown in Fig. 20A is in the illustrated continuously wound embodiment. For example, in one implementation, the windings start at terminals 2012 at the first end 2002 and traverse each of the winding channels of each spiral element 2000, ending with the winding end at a terminal at the far end 2004, The 2030 Swing Coupling , then, allows the spiral elements to articulate t with respect to each other.
Figure 20B illustrates one such exemplary hinged spiral element at the end of the 2050 assembly. As an alternative to continuous winding, each of the spiral elements can be wound individually so that the start and end ends stop. the winding resides in a single spiral element. The spiral wound elements can then be assembled (eg via a snap fit) so that they are coupled via their respective pivot couplings 2030. Referring now to Figure 21, an exemplary substrate assembly 2100, using the spiral elements of, for example, Figure 19A, which are sandwiched between a pair of substrates, is shown and described in detail. Specifically, spiral elements 1900 are shown sandwiched between an upper substrate 2110 and a lower substrate 2112. In the illustrated embodiment, the spiral elements are electrically and mechanically connected to the substrates via a surface support connection, the substrates (which they may be heterogeneous or homogeneous in nature), in an exemplary embodiment, they are constructed of a copper-covered fiberglass material. Copper is subsequently | recorded to route circuit between the individual spiral elements in order to complete a desired electrical circuit, such as the aforementioned Rogowski principle current detector circuit, discussed elsewhere here. Printed circuit board substrates 2110, 2112 may constitute single layer substrates, or alternatively may be of a multilayer type substrate. In addition to the routing circuit, these substrates may, in some embodiments, also include assembly locations for distinct electronic components or, alternatively, may incorporate electronic circuit elements (eg, capacitive or inductive elements) within the body of the substrate itself. The substrates also include interface terminals that allow the 2100 circuit assembly, physically and electrically, to interface with an external device. This illustrated embodiment is desirable where it is advantageous to electrically couple each of the spiral elements with one another using mass termination processes such as IR reflux. Although surface mount connections are primarily considered, it is appreciated that other techniques, such as through hole terminals, could also be used not only for the 1900 spiral elements for the interface terminals, as well (not shown).
Referring now to Fig. 22, an exemplary embodiment of a double articulated spiral assembly 2200 is shown and described in detail. Specifically, although many of the foregoing hinged embodiments shown only include a hinged coupling on one side of the coil device (i.e., on the inner diameter portion of the spiral elements), the hinged spiral assembly of Figure 22 utilizes by articulated tions that occur on opposite portions of the spiral element. Specifically, the spiral element centers! The 2250 illustrated has a 2220 internal swivel coupling as well as an external 2240 swivel coupling. The use of this arrangement allows Rogowski coil devices to be arranged in more complex geometries than circular or oval type geometries. , discussed here previously. See, for example, the "zigzag" spiral arrangement of Figure 24, which can be | benefit from the flexibility obtained via the use of a double articulated spiral assembly. In an example implementation. Each of the spiral elements will be universal in nature so that each spiral element is structurally identical to allow the production of spiral elements from a single tool. The assembler will then distribute these spiral elements into a set by choosing whether a given spiral element will use the internal swivel coupling, the external swivel coupling, or a combination of the two, as is the case with the swivel element. center spiral illustrated in figure 22. Alternatively, multiple tools and spiral element designs can be used to obtain a desired geometry. For example, separate spiral elements can be created for: (1) internally hinged coupled spiral elements; (2) external hinged coupled spiral elements; and (3) the double-hinged coupled spiral elements. Referring now to Figures 23A and 23B, parallel pairs of so-called "zigzag" spiral arrangements are shown and described in detail. It is appreciated that the term "zigzag", as used in the present context, only denotes and alternates pattern (which may alternate regularly or irregularly) and is now limited to shapes or sizes or configurations.
Figure 23A illustrates four (4) 2300 spiral elements arranged around a header 2350 with a rectangular cross section, although other header geometries (eg, square, round, etc.) could be accommodated, readily. These four (4) spiral elements are each arranged in pairs 2320 in the illustrated mode and are coupled via their respective internal articulated coupling 2330. In this mode, the articulated coupling is positioned beyond the busbar, then, from the ends 2332 of the non-hinged portions of each of the spiral elements.
Figure 23B illustrates an opposite arrangement, where the paired spiral elements 2320 are coupled via their respective outer hinge coupling 2360, thus positioning the hinge away from the | 2350 collector bar.
Figure 24 illustrates an exemplary implementation of the zigzag spiral arrangements illustrated in Figures 23A and 23B as they are arranged around a rectangular collector bar 2450. Specifically, Figure 24 includes two pairs of elements coils 2410 which are connected via their outer articulated coupling 2412; that is, those pairs of spiral elements disposed along the length dimension of the collector bar 2450, while the pairs of spiral elements 2420 disposed at the ends of the collector bar are connected via their internal hinged coupling 2422. Spirals arranged at the ends of the collector bar are connected to the two pairs of spiral elements arranged along the length dimension of the collector bar via their respective internal hinged couplings 2422. Each of these spiral elements are further arranged within a housing 2460 which includes a number of alignment features 2470 which are, in this embodiment, molded directly into the housing itself. These alignment features keep the spiral elements in place! in their desired positions, so that the angular relationships between adjacent spiral elements are advantageously maintained in a desired and repeatable relationship which provides, inter alia, manufacturing consistency and performance.
Figure 25A illustrates an alternative current sensing device that can be used with multiples of the spiral elements described herein. Although many of the current sensing device embodiments discussed herein are closed loop, the embodiment of Fig. 25A uses a non-closed loop configuration. Specifically, the 2500 spiral elements are arranged so that the start and finish spiral elements do not actually complete a three hundred and sixty degree (360) loop around the 2560 conductor(s) to be. in) detected(s). This — configuration is particularly useful, inter alia, where it is desirable to measure the current in the conductor without necessarily having to (1) thread the conductor through the center of the Rogowski device or the center of the abatement device | catalyst selective; or (2) disassembly and reassembly of the Rogowski device around the conductor to be measured.
Figure 25B illustrates a dis-
alternative position for an unclosed loop.
Referring now to Fig. 26, a current sensing device 2600 with an integrated busbar 2660 is shown and described in detail.
Specifically, the current sensing device of Figure 26 includes a housing 2610 that incorporates a plurality of segmented spiral elements (not shown), such as those elements previously described herein.
However, the current sensing device of Figure 26 includes an integrated conductor 2660 that passes through the central portion of the underlying device that interfaces with the source of current to be measured.
In one embodiment, the integrated conductor interface interfaces with a socket connector so that when the current sensing device is connected to these socket connectors, current is able to pass through the transmission side of a power distribution system for the load side of the power distribution system (eg a consumer's house). In an alternative configuration, the integrated busbar is electrically connected to a printed circuit board that acts as the interface between the transmission side of the power distribution system and the load side of that same system.
In this way, the current sensing device with integrated busbar acts as a modular current sensing device that connects/connects at the interface between the load and transmission side of a power distribution system, in order to allow measurement of power current distributed to the load side of the power distribution system.
Current sensing terminals 2620 are also illustrated which provide the signal information necessary to measure current passing through the integrated busbar.
Figure 27A illustrates a finished packaging option which, in the illustrated embodiment, includes a number of surface mount terminals 2720 integrated into housing 2710 of device 2700. These surface mount terminals act as an interface to the measurement circuitry. underlying current of the device. Figure 27B illustrates this 2750 finished packaging option assembly mounted on a printed circuit board. This finished packaging option is also mounted on, or has a conductor to be measured passed through the central opening 2712 of the device. In this way, the illustrated finished packaging option can be easily integrated into the interface equipment used to record and/or distribute current sensing measurements obtained from the underlying circuitry of the device. Furthermore, although surface mount terminals are illustrated in the embodiments of Figures 27A and 27B, it is appreciated that such surface mount terminals can be replaced by other types of terminals, such as through hole terminations, which are connected via a connector. which can be bonded and/or a eutectic solder connection to a through hole via a printed circuit board. Furthermore, although the surface-mounted terminals are illustrated as self-conducting terminals, it is appreciated that the metal surface-mounted or insert molded or post-inserted terminals could also be used in place of the self-conducting terminals shown.
Referring now to Fig. 28, a multiple sensing device 2800 with integrated crosstalk compensation is shown and described in detail in the illustrated embodiment, the multiple sensing device includes three (3) current sensing devices in non-closed loop configuration.
2850. In addition, although unclosed loop configurations are shown, it is appreciated that closed loop configurations such as those described here can be readily overridden in the sensing device —multiple of figure 28. Multiple sensor modules are preferably housed within a single 2810 housing.
In one embodiment, the multiple sensor module is of the integrated busbar type, discussed previously with respect to Figure 26. In an alternative embodiment, the multiple sensor module constitutes a finished packaging option, such as that discussed with respect to Figures 27A and 27B. In an example implementation, the multiple sensor module will include shielding (not shown) between adjacents of the | sensor measurement in order to prevent crosstalk interference between adjacent conductors to be measured. In an example application, the 2800 multi-sensor device is used in multi-conductor applications where there are multiple conductors that need to be measured. Alternative Winding Configurations Referring now to Figs. 29A-30, various arrangements for alternative winding configurations for use, for example, with the segmented spiral elements described herein are shaped and described in detail. As shown in Figure 29A, an exemplary center start/center finish winding technique 2900 is illustrated. This configuration has been shown, in some winding implementations, to reduce the noise error seen with high voltages in Rogowski device implementations. In the illustrated example, the sensor winding starts at the center of the array, as opposed to the end of the array, as described, for example, in Figures 18A—188 below, The winding. The sensor winding starts at a winding terminal 2910 (for example, an 1890 start end clip type winding terminal illustrated in Figure 18A described hereafter). The winding, in the illustrated embodiment, traverses the spiral elements as illustrated at 2902 (i.e., the first four Illustrated layers traverse along spiral elements three, two, one, two, three, four, five, six, five and four). Upon completion of the winding operation for the four illustrated layers, the sensor winding is terminated at winding terminal 2920. The shield layer is then wound starting —at terminal 2930, where it traverses in the opposite direction of the sensor winding. (ie, along spiral elements four, five, six, six, five, four, three, two, one, two, three). In this way, a segmented spiral Rogowski device can be rolled up from a central position of the assembly, as opposed to the ends.
It will be appreciated that, although shown with six (6) segmented spiral elements, any number of spiral elements may be used consistent with the principles of embodiments of the present invention. dog.
In addition, although the sensor winding and shield windings are illustrated starting and ending at the center of the assembly, it is appreciated that it may be desirable, in some cases, to start far from the geometric center.
For example, the sensor and shield windings can start between spiral elements two and three, as opposed to between elements three and four, as shown.
Additionally, although the sensor and shield windings are shown to originate in the same general location, it is appreciated that this will not necessarily have to be the case, ie the sensor windings could originate between elements of spiral three and four, although the armor windings could originate between elements four and five. These and other variations may be evident to someone of ordinary skill given the present description. Referring now to Fig. 29B, yet another alternative configuration is shown which can be used, for example, in the PE mode illustrated in Fig. 29A.
In a first implementation discussed in the context of Fig. 29A (ie, a four-layer sensor winding modality), the first two layers are wound in a first direction (eg, clockwise) , with the two subsequent sensor winding layers being wound in an opposite second direction (eg counterclockwise). This setting reduces the interwinding capacitance effects seen in the sensor array.
As an alternative implementation, and in the context of Fig. 29A, the sensor winding process starts at start termination 2910 where it traverses spiral elements one to six to complete layer 1 and back 2960 to spiral element one to complete the layer two in a first winding direction (eg clockwise.
Upon reaching spiral element one, the sensor winding is traversed by spiral elements one to six and back to one in a second winding direction (eg counterclockwise) to complete layers three and four. |
Referring now to Figure 30, a 3000 bench winding configuration is shown and described in detail. Specifically, Figure 30 illustrates a winding technique for a single spiral element 3002. The winding technique uses so-called winding banks 3040,.3050,3060 which each include multiple layers (ie. i.e, first layer 3010, second layer 3020 and third layer 3030). Each bank of winding in the illustrated embodiment reduces the number of windings as the process progresses from the first layer to the third layer. This winding configuration reduces the amount of interrelationship capacitance seen in the device, thus improving electrical performance across a given electrical characteristic range (eg, frequency).
Although the illustrated bank winding configuration includes three (3) distinct winding banks, it is appreciated that more or less winding banks could readily be substituted for the three that are illustrated. Furthermore, although three layers of windings are shown for each winding bank, it is appreciated that more or less layers of winding could also be used, depending on the performance requirements of the device.
Furthermore, although each bank of winding is shown with a "scaled" number of windings per layer, it is appreciated that certain embodiments may utilize banks of windings with an equal amount of turns per layer. These and other alternatives will be readily evident to someone of common ability given the present description.
Alternative Shielding Configurations Referring now to figures 31 — 34B, various shielding configurations for use in the current sensing devices described here are shown and described in detail. Various embodiments described here consist of one or more layers of sensor winding (ie, a layer of winding that is used to detect current in a Rogowski-type device), along with one or more layers of blin- | which are used to improve device performance by mitigating the harmful effects of electromagnetic radiation. In a typical context, the winding and shielding layers are formed from an insulated winding, that is to say in a conductive wire with an insulating coating disposed across the conductive portion. However, it is recognized that, in some embodiments, it may be advantageous to remove the insulating layers from the shield layer so that the shield layer consists of non-insulated windings. These and other variations will be considered as readily available alternatives to the various modalities for the various modalities described here.
Referring now to Fig. 31, a first shield configuration for use in a current sensing device 3100 using shield windings of alternating direction is described. In the illustrated embodiment, the first spiral segment has a shield layer wound in a first direction 3110, 3130 and 3150. In addition, the 2nd, fourth and sixth spiral elements are each wound. - do in the same direction 3120, 3149, 3160.
Although the illustrated embodiment of Figure 31 shows the winding direction of the alternating shielding layer from the spiral element to the spiral element, it is appreciated that it may be desirable, in some cases, to alternate winding directions for the layer(s). s) shielding every two or more spiral segments. For example, in the context of the center start/center finish winding technique illustrated in Figure 29A, the shield layer may, in one embodiment, be wound in a first direction with respect to spiral elements one to three, while four to six spiral elements have a shielding layer that is wound in an opposite direction. Furthermore, where a given spiral element has two or more layers of shielded windings, each layer may be wound alternately (ie, a first layer wound in a first direction and a second layer wound in an opposite second direction) .
Referring now to Fig. 32, a configuration of en- | interleaved shielded bearing, exemplary, 3200 is shown and described in detail. Figure 32 illustrates a cross-sectional view of a spiral wound element 3202, with layers of winding originating from one or more columns of terminals 3204. The illustrated configuration shows three (3) layers of windings. first layer 3210, second layer 3220 and third layer 3230. How much (4) or more layers could also be used. In the illustrated mode. The shield layers are interspersed with the sensor winding layers. For example, layers 3210 and 3220 consist of shielding layers, while layer 3230 is composed of a sensor winding layer. In the context of a four (4) layer embodiment, with the fourth layer disposed on top of top layer 3210, the fourth layer and layer 3230 could be shielding layers, while layers e.g. 3210, 3220 consist of sensor winding layers. These and other interspersed modalities will be readily evident to one of common ability given the present description.
Figure 33 illustrates another alternative shield configuration. Specifically, Figure 33 illustrates a spiral element assembly 3300 (here a double hinge coupled spiral assembly is shown, although other assemblies described herein could be readily replaced).
Each spirally wound element 3310 includes a shield layer 3320 disposed over the sensor windings. In an exemplary implementation, the shielding layer comprises a copper foil which is cut to a predetermined width so as to fit within the spiral 3310. Alternatively, the copper foil may be replaced by a copper braid which is arranged to be disposed over the sensor windings of the assembly or yet other types of shielding materials and/or configurations may be used.
Referring now to Fig. 34, yet another shielding configuration is illustrated in the context of a Rogowski device 3400 using an integrated housing 3420. In the illustrated embodiment, a | copper layer (or other suitable shielding material) 3410 is disposed along central opening 3402 of the housing.
Exemplary Applications of Current Sensing Apparatus The exemplary current sensing apparatus described herein can be used in a large number of applications and/or where it is desirable to measure the current in a conductor without otherwise disturbing the current-carrying conductor. One of these common applications is in the incorporation of current sensing apparatus in electrical meters for use in residential, commercial and industrial applications. By measuring the current being consumed by an electricity consumer and passing that information to the utility company via a network interface on the meter, the service utility company or other entity can better assess what to charge of its consumers and/or better understand the energy being consumed by all the various parts of an electricity grid or system.
o As well as being resistant to tampering and electromagnetic interference, current sensing apparatus, such as Rogowski coils, has wide applicability in various applications, included in the recent push for so-called smart grids. In addition to use in power distribution metering applications (such as circuit breakers, residential and industrial monitoring stations, etc.), the use of current sensing apparatus in a wide variety of appliance applications that use large amounts of current ( eg electric welders and engine controls) are also considered.
Multi-Coil Current Sensing Apparatus Referring now to Fig. 15A, a first exemplary embodiment of a multi-coil Rogowski coil device is illustrated. Specifically, the multi-coil Rogowski coil device of Figure 15A comprises two (2) Rogowski coil devices of the type previously illustrated with respect to Figure 1 above, arranged in a "stacked" or juxtaposed arrangement. Although illustrated with the coil mode of Figure 1, it is appreciated that any | one of the current sensing apparatus embodiments described herein may readily be stacked in this manner (including without limitation the free space or spiral-free embodiments described elsewhere herein). In addition, the upper and lower Rogowski coil devices are shown, each with only a single coil element or segment 1510 and 1520, respectively. It should be recognized, however, that in practice each of the Rogowski coil devices of the illustrated embodiment will have eight (8) wound coils, the single wound coil is shown in Figure 15A, just to more easily illustrate the relative displacement. between the top and bottom Rogowski coil devices. You will recall from the previous discussion of prior art Rogowski coil devices that these prior art devices are uniform in their distribution of their windings (i.e., they are a. unsegmented). Furthermore, as the Rogowski coil devices 100 illustrated in Figure 15A are segmented, it is expected that there will be some. flow leakage or "imperfection" in the gaps between the wound coils of these devices. Consequently, by stacking the Rogowski coil devices in Fig. 15A in close proximity to each other and angularly displacing the top segmented winded coil 1510 from the bottom segmented winded coil 1520 (and combining the outputs of the two coils ), the devices behave more like an ideal Rogowski coil with a uniform unsegmented winding distribution.
It will be appreciated that although only two spools are shown in the embodiment of Figure 15A, three (or more) spools can be stacked in this manner, if desired. For example, it may be desirable to use three (3) such spools in a stacked arrangement (not shown), with the gaps between segments in the middle spool corresponding to the spool segments of the upper and lower spools. So the leakage flux from the middle coil is addressed substantially and symmetrically (from the top and bottom) by the upper and lower coils, respectively. In another configuration (such as where the clearances are appreciable in size relative to the length of the spool segments), the placement of the d spools of the respective stacked spools may be "in phase" with respect to the slack of the first, by example, a first coil in a vertical position zero (0) at an angular position zero (0), the second coil in a vertical position one (1) on top of the first coil at an angular position zero plus x, the third coil in a vertical position two (2) at the top of the second coil at an angular position zero plus y (where y is greater than x) and so on. Generally speaking, for an appreciable effect on leakage or accuracy to occur due to the addition of more coils, the coils must be offset from each other in azimuth somewhat (ie, segments of a coil overlap with clearances on another coil); however, this is not always the case.
O At least some effect on accuracy /(leakage can be obtained in certain configurations by simply stacking two or more spools with their segments aligned, due to the fact that the slack leakage of one spool couples with the adjacent segments of the spool. (s) other coil(s), even when adjacent segments of the second coil are not aligned with clearances.
Figure 15B illustrates the top-down view of the two Rogowski coil devices of Figure 15A. Specifically, the angular displacement can be clearly seen in Fig. 158 with the bottom wound spools 1520 offset or offset relative to the top wound spools 1510. Although the Rogowski coil device of Figs. it is recognized that three (3) or more Rogowski coil devices can also be stacked with their outputs combined and angularly offset from one another in order to provide more optimal behavior when measuring the current passing through a conductor to be measured.
Figure 15C illustrates another embodiment of a stacked Rogowski coil apparatus. Specifically, Figure 15C illustrates a variant for the apparatus shown in Figure 15A, in which adjustment covers 1530 | are placed around Rogowski coil devices 100. These covers 1530 preferably are made of a molded polymer and have features (not shown) that allow the covers to rotate with respect to one another while coupled. As the devices are allowed to rotate 1534, a user can effectively adjust the output of the stacked Rogowski coil devices in order to optimize the performance of the stacked Rogowski coil device. The adjustment covers also include a hinge 1532 which allows the covers and Rogowski coil devices to be positioned around the conductor to be measured without requiring the conductor to be threaded through the central opening 1536.
Referring now to Figure 15D, Rogowski coil apparatus 1540 is shown and described in detail. The apparatus of Figure 15D. includes three (3) Rogowski coil 100 devices, although the half device has been removed from view in order to better illustrate the internal operation of the stacked apparatus 1540. The Rogowski 100 coil devices are received within a protective cover 1550 which is illustrated in cross-section. Devices 100 are similar in construction to those devices shown in Figure 1; however, they were, in an exemplary modality, constructed of a direct laser sintering (LDS) polymeric material. Each of the devices was formed on two (2) conductive coated surfaces 1540, which are electrically coupled to the respective ends of the segmented Rogowski coil windings. Rogowski 100 coil devices are received within a 1550 channel formed within the protective cover.
1560. These 1550 channels act as a guide that allows the Rogowski 100 coil devices to rotate within the 1560 cover. The 1560 cover is also preferably formed of an LDS polymeric material, thus allowing it to the 1550 channels are also conductively coated. As a result, the conductive channels 1550 of the cover are electrically coupled to the conductive pads 1548 of the Rogowski coil devices. Various interfaces (including LDS polymer interfaces) between the individual devices 100 and the cover 1500 may be utilized, such as those described in copending U.S. Patent Application Serial No. 12/482,371, filed June 10 of 20089 and entitled "Miniaturized Connectors and Methods", the contents of which are incorporated herein by reference in their entirety. Conductor channels 1550 are then electrically coupled together and also to output terminals 1562. These output terminals 1562 can then be attached to outer conductors (not shown) or alternatively mounted as a contact of surface mounting or through hole in an external substrate (not shown).
As an alternative to using LDS polymers, the Rogowski 100 Coil Devices and 1560 Cover could also be constructed as a composite structure. Specifically, the pillows. conductors 1548 in the Rogowski coil device and the conductor channels 1550 are constructed of a metallic alloy placed in the underlying polymeric structures. These metal alloys can be either insert molded or post-inserted into preformed openings present in the cover and in the Rogowski coil head, respectively. Furthermore, these metal alloys preferably are molded so as to act as a spring and provide additional contact force while the Rogowski coil devices are rotated within the casing. The Rogowski coil devices are rotated within the cover via a protrusion 1566 through an opening 1564 located in the cover 1560. By manipulating the protrusion 1566 in a lateral (azimuth) 1568 direction, the individual Rogowski coil devices can be adjusted. - from within the 1540 set.
Referring now to Fig. 15E, a Rogowski coil apparatus, stacking concentrically disposed, 1570 is shown and described in detail. Specifically, stacked Rogowski coil apparatus 1570 comprises an inner Rogowski coil 1580 and an outer Rogowski coil 1575. Both the inner and outer Rogowski coils are adapted to rotate in a circumferential direction 1572 | with respect to each other. Similar to the stacked concepts illustrated in Figures 15A - 15D, the concentrically stacked Rogowski coil apparatus of Figure 15E allows the windings 1577 of outer coil 1575 to be positioned adjacent to the unoccupied intermediate segments 1582 of inner coil 1580. Similarly, the windings 1584 of the inner coil 1584 are positioned adjacent to the unoccupied intermediate segments 1579 of the outer coil 1575. The respective ends of the inner and outer Rogowski coil devices are then electrically coupled together to provide a combined output for a conductor to be measured.
In yet another exemplary embodiment, two (2) or more of these stacked, concentrically arranged 1570 Rogowski coil apparatus can be placed in a top-to-bottom arrangement (similar to that shown with retraction to Figure 15A), thus, adding or- : 15 redundancy layer to help correct distortions in electrical NM performance due to coil segmentation. In this configuration, it is desirable that the inner coil winding portions 1584 be placed adjacent to the inner coil's unoccupied intermediate segments 1582 adjacent to the inner coil's unoccupied intermediate segments 1579 of the adjacent outer coil. In another variant, a stacked/concentric "hybrid" configuration (not shown) is provided. In this variant, the individual coils of the multi-coil set are of different radii, though not such as to fit entirely within each other (ie, the outer diameter of a coil is such that it is larger than the diameter of " internal hole" of the next adjacent coil, so that they rest in a stacked configuration, but with the coils having different diameters. The variation of the coil diameter as a function of the vertical position can be progressive (eg the diameter of the coil. coil in a vertical position zero (0) being smaller than that of the next highest coil and the diameter of that next highest coil being smaller than that of the third coil above it and so on) or assumes other patterns ( such as an "hourglass", in which the lower coil is of a larger diameter than the (second) coil directly above it and the coil directly above it.
ma of that second coil is also of a larger diameter). Furthermore, where viewed primarily as adjustable modalities, the stacked Rogowski coil devices of Figures 15A - 15E are not so limited.
In fact, it may be desirable in some modalities to maintain a fixed relationship between the adjacents of the Rogowski coil devices, thus simplifying assembly.
It will also be appreciated that in another modality, the spacing or vertical arrangement of the different coils (whether in a ""stacked" or ""concentric" configuration) can be varied, thereby increasing/decreasing the coupling or interaction of the coils .
For example, the vertical height between stacked coils can range from zero (0) to literally any value consistent with the form factor of the application.
Obviously, greater The coupling effect will be obtained when the coils are immediately close to each other, but it is considered by the present invention that the "adjustment" of the set can also comprise the variation of the vertical spacing of coils in the configurations concentric or stacked.
In one variant, this variable spacing is accomplished by simply replacing non-conductive spacers (eg flat toroids or "washers" of prescribed thickness made, for example, of a polymer, paper, kapton, etc.) between the individual coils.
In another variant, the box containing the spools can be configured so that the stacked spools can reside at different elevations with respect to one another.
Many other techniques for allowing variation in the spacing between coils will be appreciated by those of ordinary skill given the present description.
It is also noted that although the aforementioned modalities of stacked and concentric (and hybrid) coil sets can be "adjusted" by varying the placement of the coils in relation to each other — either vertically, horizontally or in azimuth or even attitude (yaw) - can also be adjusted to obtain the desired level of performance due to your constitution.
For example, in a set modality, the user/installer is provided with a | plurality (eg two or more) of very low cost, less accurate coils. Each of these coils may, for example, have only a small number of segments, relatively large spacing between segments, and/or less back density in each segment, so that they are a coarser approximation of the "perfect Rogowski coil". " (though still very cheap to manufacture). It may be that a user of the assembly requires only a rough, low-precision approximation of the sense parameter(s) (eg current through a conductor) and therefore the use of a single one of the coils previously mentioned within the set may suffice for these purposes. Alternatively, another user of the assembly may require much higher levels of accuracy in their intended application, these levels of accuracy cannot be achieved by using just one of the low-precision coils, although they can perhaps be achieved with two or three of these coils used in stacked/concentric/hybrid configuration. In this way, a modality of the invention is configured so that coils can be added or subtracted by the user, as required, in order to obtain their desired level of accuracy, while also obtaining the implementation more cost-effective (in contrast to a prior art "one-size-fits-all" approach, where the accuracy/accuracy of the device is effectively fixed).
The foregoing methodology can also be applied to facilities where large numbers of individual or aggregated coils may be required, such as a public company implementing a customer monitoring program. For example, where the electrical meter base installed for the company's customers is substantially homogeneous, the company can "tweak" the device installation into an exemplary or representative meter and then simply duplicate that installation throughout. of the other meters within the customer base (without having to adjust each of them individually). Therefore, the company can buy an "adjustment kit", which can have, for example, a plurality of different types, diameters, winding densities, segment spacing and configurations. rations of coils/coil sets and adjust the prototype or representative installation in order to optimize performance and/or cost (ie, obtain the desired level of accuracy at the lowest possible cost). Once the optimal configuration (or configurations for the respective types of customer installations) is known, the company can then simply purchase the cost/* performance optimized configurations en masse from a supplier, thus avoiding the waste and the cost of "leftover" or unused parts (eg coils) that would result from purchasing a plurality of individual tuning kits.
It should also be noted that some of the previous modalities consider the use of homogeneous coil configurations. For example, in the stacked assembly described above, the first spool could have a range of segment winding density and spacing of 2 segments/number of segments. The second coil, however, could use a different density/ spacing/ number, while having the same effective radius and/or height. Furthermore, as noted previously, the coils may also (or alternatively) have different coil heights and/or radii, different cross-sectional profiles, etc. Therefore, a set that can "mix and match" different coil types is considered here. For this assembly, the housing (if any) can also be configured to accept the different coil types so as to avoid the user/installer having to look for a different housing type depending on the selected combination/configuration of component coils. This "universal" housing can readily be constructed to accommodate the various possible configurations, satisfy the objects of relative space conservation, low cost, maintaining the coil(s) in a desired orientation relative to the( s) monitored conductor(s) and so on.
Figure 35A illustrates an embodiment of substrate assembly 3500 using three different printed circuit boards. Specifically, the embodiment of Figure 35A includes an upper substrate 3510, a lower substrate 3512, and an intermediate substrate 3514. tracts are a number of spiral elements 3520, which collectively form a multi-coil Rogowski coil device.
In one embodiment, the multi-coil Rogowski coil device of Fig. 35A comprises two (2) Rogowski coil devices of the type previously described with respect to Figs. 19A-19C above, arranged in a "stacked" arrangement or juxtaposed.
However, other modalities, such as those illustrated in Figure 20A, can be readily substituted or even intermixed (in terms of different layers). Note that since the Rogowski coil devices, illustrated in Figure 35A, are segmented in nature, it is expected that there will be some loss of flux or "imperfection" in the clearances between the wound coils of these devices for that reason.
As a result, through the stacking of the Rogowski coil devices in Figure 35A, the combined O-devices behave more like an ideal Rogowski coil with a uniform, unsegmented distribution of windings.
Although the two Rogowski coil devices in Fig. 35A are illustrated with their respective coil elements aligned, it is recognized that the top and bottom Rogowski coil device spiral elements can be angularly offset from each other, similar to in modalities previously discussed here in connection with Figures 15A - 15E.
Furthermore, it will be appreciated that, although only two spools are shown in the embodiment of Figure 35A, three (or more spools can be stacked in this manner, if desired.
For example, it may be desirable to use three (3) of these spools, with four (4) substrates in a stacked arrangement (not shown), with the gaps between segments in the middle spool corresponding to the spool segments of the top spools. and lower, so that the loss of flux from the middle coil gaps is directed substantially symmetrically (from top to bottom) by the upper and lower coils, respectively. Alternatively, the placement of the spiral elements of the respective stacked coils can be "in phase" with respect to the clearances of adjacent Rogowski coil devices, as discussed previously herein. |
Referring now to Fig. 35B, an alternative arrangement of the multi-coil Rogowski coil device 3500 of Fig. 35A is shown and described in detail. Specifically, in the embodiment illustrated in Figure 35B, the top and bottom substrates have been avoided in favor of exclusive circuit routing on a centered substrate
3530. In other words, each of the terminal locations for each of the spiral elements of the upper and lower Rogowski coil devices is located on the central substrate. The interface circuit to the external processing circuit (not shown) is thus located on a single substrate for the upper and lower Rogowski coil devices. In an exemplary implementation, the Rogowski coil devices are "combined", that is, the electrical circuit routing O between individual spiral elements alternates between the top and bottom Rogowski coil devices, as best. illustrated in Figure o 35C. In other words, the circuit routing will go from a first spiral element 2550 in the lower Rogowski coil device to a first spiral element 3552 in the upper Rogowski coil device and back down to a second. spiral element 3554 in the lower Rogowski coil device and so on for spiral elements 3556 and 3558, etc. As a result, the upper and lower Rogowski coil devices and their circuitry in the circuit located on the substrates will act to create a unique two-layer Rogowski coil device, Manufacturing Methods for Current Sensing Apparatus Making Reference Now to Figure 10, a first exemplary method for manufacturing a current sensing apparatus 1000 is shown and described in detail. Specifically, figure 10 illustrates the methodology for manufacturing the current sensing apparatus illustrated in figures 1-—-18B. In step 1010, coils without spirals are wound on a mandrel. one at a time, or alternatively they can be wound together to avoid having | we interconnect them in a later processing step. These coils can be wound using a single layer of windings or alternatively in a multi-layer configuration. The wound coils are then bonded together via the application of heat. The manufacture of coils without spirals is described, inter alia, in United States Patent Application, co-owned Serial No. 11/203,042, filed August 12, 2005 and entitled "Stacked Inductive Device and Methods of Manufacturing" , the contents of which are incorporated herein by reference in their entirety.
In step 1020, the wound spools are threaded into a preformed copper wire return loop (Figure 1, 104) in an exemplary embodiment, the copper wire return loop is formed so as to be , generally "C-shaped, with a relatively small gap between O the beginning and end of the copper wire loopback. In step 1030, each of the coils without spirals (figure 1, 2 102) is positioned into corresponding cavities (figure 1A, 112) of the segmented head (figure 1, 110).
In step 1040, the copper wire return loop is press-fitted into the radial positioning slot (Fig. 1B, 114) of the segmented head. In a variant, the return side can be secured to the radial slot via the use of an epoxy adhesive.
In step 1050, the finishing lead wire from the last wound bobbin is attached to one end of the return wire loop. Such fixation can utilize any number of known techniques, such as eutectic welding operations, sonic welding and the like.
In step 1060, the lead wire from the start of the first wound coil and the start of the loopback to the connection wires for the current sensor apparatus are connected. In an exemplary embodiment, the connecting wires comprise twisted pair, wires. shielded conductors.
At step 1070, the coil assembly is placed inside or otherwise encapsulated with a protective wrap or coating, thus completing assembly. In an exemplary modality, the set of | Coil is placed inside an overlapping protective plastic shell case. The overlapping nature of the plastic shell housing provides enhanced protection against high potential resistance (also known as "Hi-Pot") by increasing the length of the gap between the wires in the current sensing apparatus and the conductor to be monitored.
Referring now to Fig. 11, an alternative method for fabricating a current sensing apparatus 1100 is shown and described in detail. Specifically, Figure 11 illustrates the methodology for manufacturing the current sensing apparatus illustrating, for example, in Figures 2 — 2C; and Figures 4-4B, In step 1110, the segmented spiral elements (Figure 2, 210) are loaded into an arbor. In an exemplary embodiment, starting at one end, each spiral element is continuously wound through successive spiral elements, so that a continuous coil winding, with no distinct interconnections, is included.
o These wound spools can be single or multiple layer in nature.
In step 1120, the return wire is threaded through respective openings (Fig. 2A, 230) of the spiral elements. In one embodiment, the return wire comprises one or more shielded twisted pair conductor wires that are pre-drawn, separated and stretched so that they can be placed through the holes provided in the spiral elements as they are seated in the chuck. In an alternative mode, step 1120 is performed before the coil winding in step
1110.
In step 1130, the spiral wound elements are removed from the mandrel as a single assembly. The removed coiled spiral element set looks like pearls on a string.
In step 1140, the end wire of the last coil is terminated at one end of the twisted pair return wire. In embodiments using two openings (see, for example, Fig. 4, 432) the return thread may be routed back through the central portion of the segmented coiled spiral elements.
In step 1150, the spiral elements are formed into their final shape (such as the exemplary torus-like or radial pattern described previously herein). In exemplary embodiments that include swivel couplings (eg, figure 2, 220), the swivel couplings are positioned so that they lie on the inside diameter of the torus-like pattern.
In step 1160, each of the spiral elements is placed within corresponding cavities or slots associated with a plastic conductor. For example, in the illustrated embodiment of Figure 4A, each spiral member 410 is placed within a respective cavity 464 of the outer ring-like head. 460. In step 1170, the initial lead wire of the first spool is terminated at the other end of the return wire loop. At step 1180, the coil assembly is placed in or otherwise encapsulated with a casing or protective coating, thereby finishing the assembly, such as that described with respect to step 1070 of Figure 10 previously discussed herein.
Referring now to Fig. 12, a third exemplary method for fabricating a current sensing apparatus 1200 is shown and described in detail. Specifically, Figure 12 illustrates the methodology for manufacturing the current sensor apparatus illustrated in Figures 3 — 3D. In step 1210, the segmented spiral elements (figure 3, 300) are loaded onto a mandrel. In an exemplary embodiment, starting at one end, the winding is secured at one end and the wire is stretched along the top slots (figure 3, 314) through all of the spiral elements. This wire must be used as a return wire.
In step 1220, and starting at the far end (from the starting point of the return wire), the wire is wound back along the length of spiral elements with windings placed on each spiral element, thus making a continuous coil winding, without | interconnections, while simultaneously wrapping through the return wire. Similar to the previous embodiments discussed above, coils can be single or multilayer depending on the design conditions associated with the particular application for the current sensing apparatus.
In step 1230, the spiral wound elements are removed from the mandrel.
In step 1240, the spiral elements are formed into their final shape (such as the exemplary torus-like pattern previously described here). With respect to the modality illustrated in Figures 3 — 3D, the return wire will run along the outer diameter of the spiral elements.
In step 1250, the finishing lead wire and the CO return wire are terminated to the conductors associated with the connecting wires (for example, shielded, twisted-pair lead wires).
o In step 1260, the coil assembly is placed inside or otherwise encapsulated with a protective wrap or otherwise encapsulated with a liner, thus completing the assembly.
Referring now to Fig. 13, yet another embodiment for fabricating a current sensing apparatus 1300 is shown and described in detail. Specifically, Figure 13 illustrates the methodology for manufacturing the current sensing apparatus illustrated, for example, in Figures 5-5C. In step 1310, the segmented spiral elements (figure 5, 510) are loaded onto a mandrel. In an exemplary embodiment, starting at one end, each spiral element is wound continuously through successive spiral elements, so that a continuous coil winding, with no distinct interconnections, is included. These wound coils can be single or multiple layer in nature.
In step 1320, the return wire is threaded through respective openings (Fig. 5, 522) of the spiral elements. In one embodiment, the return wire comprises one or more shielded conductor wires from | twisted pair, which are pre-extracted, separated and stretched so that they can be placed through the holes provided in the spiral elements as they are seated on the mandrel. In an alternative mode, step 1320 is performed before coil winding in step
1310.
In step 1330, the spiral wound elements are removed from the mandrel. The coiled spiral elements, because they are interconnected, are removed into a single assembly.
In step 1340, the end wire of the last coil is terminated at one end of the twisted pair return wire.
In step 1350, the spiral elements are formed into their final shape (such as the exemplary torus-like or radial pattern described previously herein). In exemplary embodiments that include swivel couplings (eg, figure 5B, 550), swivel couplings are positioned so that they lie on the inside diameter of the standard torus-like CU.
In step 1360, each of the spiral elements is placed within corresponding cavities or slots associated with a plastic conductor. Similar to that shown in the illustrated embodiment of Figure 4A. In step 1370, the initial lead wire of the first coil is terminated at the other end of the return wire loop.
In step 1380, the shield layer is placed inside or otherwise encapsulated with a protective wrap.
Referring now to Figure 14, yet another method for fabricating a current sensing apparatus 1400 is shown and described in detail. Specifically, Figure 14 illustrates the methodology for manufacturing the current sensing apparatus illustrated, for example, in Figures 6-6B. In step 1410, the segmented spiral elements (figure 6, 610) — are loaded onto a mandrel. The return wire is, starting at one end, routed into the cavity (figure 6, 630) on the outer diameter of the spiral elements. Then, starting at the opposite end, each of them- | The spiral winding is continuously wound through successive spiral elements, so that a continuous coil winding without distinct interconnections is included. These wound spools can be single or multi-layered in nature and are positioned over the return wire. In step 1420, the spiral elements are removed from the mandrel As the spiral wound elements are interconnected, they are removed in a single assembly attachment.
In step 1430, the end wire of the last coil is terminated at one end of the twisted pair return wire.
At step 1440, the spiral elements are formed into their final shape (such as the exemplary torus-like or radial pattern described previously herein).
o In step 1150, each of the spiral elements is placed within corresponding cavities or slots associated with a plastic conductor, similar to that shown in the illustrated embodiment of Figure 4A. In another embodiment, each of the spiral elements is placed within the bottom portion of an overlapping shell-shaped wrap box.
At step 1460, the initial lead wire of the first spool is terminated at the other end of the return wire loop.
Finally, at step 1470, the coil assembly is placed inside or otherwise encapsulated with a protective wrap. In an embodiment where a plastic shell shaped wrapping box is used, this step is performed by placing and securing the plastic shell shaped wrapping box over the assembly.
Referring now to Figures 18A-18S, an embodiment of the methodology for assembling an exemplary Rogowski coil device of the invention is shown in detail. Figure 18A illustrates an exemplary first step in the manufacturing process. In Figure 18a, the lead-end clip 1890 is inserted into a respective opening located in the lead-end spiral segment 1810. 1890 end clip is a variant fabricated from a conductive sheet of metal, which is stamped and optionally coated to protect the clip's surface finish. After insertion, the clip is subsequently curved. This 1891 curvature is, in the illustrated example, formed at a 60 degree angle with respect to the uncurved portion of the 1890 clip. Alternatively, the initial end clip can be molded by insertion into the spiral element during the injection molding process. . In an exemplary process, the clip is formed away from the surface of the spiral segment, manually, subsequent to insertion.
In addition, exemplary embodiments incorporate notches in the end clip's bend line so as to reduce the force required to perform the bending operation, thus reducing the possibility of fracturing the spiral segment during the bending operation. .
Figure 18B illustrates the insertion of the steel end clip. 15 bar 1892 in the 1810 finish end loop segment.
' Note that the spiral segments themselves are identical between the one shown in Figure 18A and the one shown in Figure 18B (ie, the start and end spiral segments are identical only with the clips being different between the segments. ). Also note that the "initial" end clip of figure 18A and the "finishing" end clip of figure 18B are disposed at opposite ends of their respective spiral segments, The finishing end clip 1892, it is also preferably not curved prior to insertion, so that the notched end of end clip 1892 is positioned over the passage through conductor passage 1893.
Figure 18C illustrates the next step in the exemplary process, where each of the spiral elements 1810 is loaded onto a winding mandrel 1870. The end clip spiral element 1810 (i.e., the spiral element discussed under With respect to Figure 18B is inserted into the mandrel first, followed by six (6) spiral elements that are devoid of any conductive clips. Figure 18A) | is inserted into the end of the string of spiral elements, with the initial end clip 1890 facing away from the other mounted spiral elements.
Referring now to Figure 18D, a polymeric cable is slid into a slot 1813 which is collectively formed by the set of spiral elements 1810. Note that the cable end is trimmed so that the cable end does not protrudes beyond the outer wall 1811 of the end spiral element flange.
In an exemplary embodiment, the cable is manufactured from an electrical grade polytetrafluoroethylene (PTFE). The illustrated diameter is 0.031 inches, although it is recognized that other shapes (ie, rectangular, polygonal, etc.) and sizes could readily be substituted in alternative designs.
This cable is used to create an alternative "column" that finally holds the O assembly in its final form.
Although illustrated as using a PTFE cable, it is recognized that other items (such as tape, etc.) could also be readily replaced in order to provide the so-called connective "column" for the finished Rogowski coil device.
Figure 18E illustrates the start of the winding process.
Specifically, the wire 1862 is wound on the spiral elements, is first secured to the winding pin 1872 of the finished mandrel and subsequently secured to the end clip 1892 twice before being routed to the spiral element winding cylinder. .
Figure 18F illustrates the remainder of the end spiral element 1810 being wound with the required yarn turn number 1862.
In the illustrated example, three (3) layers of yarn are wound on the spiral element with fifty-two (52) turns of yarn being wound on each layer.
The layers are constructed with the first layer being rolled left to right, the second layer being rolled right to left, and the third layer being rolled, again, left to right, though other numbers layer and/or pattern description may be used consistent with the invention.
For example, all turns (eg 52 in this example) could be wound | on a single layer in one direction, Alternatively, a two-layer pattern back and forth could be used.
Figure 18G illustrates the routing of wire 1862 from the newly wound end spiral element to an adjacent spiral element.
Note that both coil elements shown include an 1863 transition feature comprised of a protrusion that includes a curved edge.
This curved edge helps prevent damage to the wire as it is routed between adjacent spiral elements.
The adjacent spiral element is then wound identically to that seen in Figure 18F (ie, with three (3) layers comprised of fifty-two (52) turns each.
The remaining 1810 spiral elements are then similarly wound as illustrated in figure 18H.
Figure 181 illustrates the end of the 1862 winding, subsequent to: being routed through each of the previously discussed spiral elements and attached to the 1890 starter clip. Similar to the end clip, the wire is and attached to the starter clip by wrapping the wire around the initial clip twice, although other mechanisms can be used.
Figure 18J illustrates the winding of shield layer 1864 on spiral elements.
As can be seen in Figure 18J, the shield layer is composed of an additional layer of fifty-two (52) turns that are wound in the opposite direction of the previously wound layers.
Also note that the wire that makes up the shield wire is the same wire that was used to pre-wind the spiral elements.
The process is continued as shown in Figure 18K, with the remaining spiral elements each receiving a shielding layer.
The use of the same yarn that was used in the previous windings is particularly advantageous from a manufacturing cost perspective.
As the spiral elements are already arranged in a winding mandrel for the purposes of automating the placement of the windings, no additional processing steps need to be carried out by an operator in order to wind the shield layer on the spiral elements. |
As a result, the only additional costs added to the device by adding the shielding layer comes from the additional time the spiral elements spend on the winding mandrel, which is minimal, along with the added material cost associated with the layer. of shielding, which is also minimal.
Furthermore, it has been found that using the same 1862 wire for the shield layer is just as effective in providing shielding for the device as other more labor-intensive methods using copper foil, etc.
Figure 18L illustrates how wire 1862 is attached to the spiral element.
Specifically, Figure 18L illustrates how the wire end of the shield layer is secured to the end spiral element.
Essentially, a single loop of 1870 tape is wound onto the spiral element and the end of the 1862 yarn is then routed through this single layer of tape and subsequently secured by further wrapping extra layers of tape.
The excess yarn 1862 and the excess tape 1870 are then trimmed.
Note that the wire end of the shield layer is not secured to the 1892 End Clip. Referring now to Figure 18M, the coiled spiral elements are removed from the mandrel and the wire is secured to the 1892 End Clip and Start Clip 1890 (not shown). Attaching the wire to these clips can be accomplished in any number of different ways. One implementation uses a resistance welding process to solar a 1866 portion of the wire to the respective clips.
Alternatively, a eutectic welding operation could be used to physically and electrically fasten offio to the respective clips. Still other methods will be recognized by those of ordinary skill in the art.
Given this description.
Figure 18N illustrates the installation of the 1850 return wire. The return wire is inserted into the central passage of the lead-end spiral elements (ie, the end with the 1890 starter clip) and routed through each one of the spiral elements until it meets the end clip element 1892 in the end spiral segment.
That thread | of return 1850 subsequently is then electrically secured to the 1892 end clip via a eutectic welding operation, resistance welding, etc. Figure 180 illustrates that the 1852 finish wire is attached to the 1890 start clip. This can instead be accomplished by using, for example, welding or resistance welding to attach the finish wire to the start clip on the start spiral element.
Figure 18P illustrates insertion of the spiral element assembly into a housing 1880. The end spiral element 1810 (ie, the spiral with tape 1870 mounted thereon) is inserted into a respective cavity 1886 located in the housing first, and subsequent spiral elements are inserted into their respective housing cavity around the ring-like shape of the housing. Note also that the end spiral element is disposed adjacent to the finish wire slot 1884 and the return wire slot 1882 associated with the housing. o Figure 18Q illustrates the finish wire 1852 and return wire 1850 after being inserted into their respective housing slots. Note that the 1852 finish wire is disposed on top of the return wire in the illustrated embodiment, which holds the wires together for the purpose of mitigating unwanted external electrical interference.
Referring now to Figure 18R, small edges of 1888 epoxy or other adhesive are inserted into each of the 1889 wells of the 1883 top housing. In addition, a light edge of epoxy is also applied to the 1887 middle hole wall. top housing 1883 is then mounted on housing 1880 as illustrated in figure 18S. The 1852 finish wire and 1850 return wire are then twisted together in a clockwise direction for the purpose of mitigating the effects of external electrical interference.
It will be recognized that certain aspects of the invention are described in terms of a specific sequence of method taps, such descriptions are only illustrative of the broader method of the invention and may be modified as required by the particular application. Certain | steps may be made unnecessary or optional under certain circumstances. Additionally, certain steps or functionality may be added to the disclosed modalities or the order of performances of two or more steps exchanged. All such variations are considered to be involved within the invention disclosed and claimed herein.
Although the detailed description has been shown, described and new features of the invention pointed out as applied to the various modalities, it will be understood that various omissions, substitutions and changes in the form and details of the device or process illustrated can be made by those skilled in the art. technique, without departing from the invention. The foregoing description is the best presently considered mode of carrying out the invention. This description is in no way intended to be limiting, but rather will be taken as illustrative of the general principles of the invention. The scope of the invention will be determined with reference to the appended claims. |

权利要求:
Claims (22)
[1]
1. An inductive current sensing device, comprising: a plurality of spiral elements, each element having a conductive winding wound thereon; and a printed circuit board with an opening therein; wherein said plurality of spiral elements are arranged around said opening and are electrically coupled together via said printed circuit board.
[2]
The inductive device of claim 1, further comprising: . a return conductor electrically coupling a front of said plurality of spiral elements with a tail of said spiral elements.
[3]
The inductive device of claim 1, wherein . At least two of said plurality of spiral elements are physically coupled to each other via an articulated coupling.
[4]
The inductive device of claim 3, wherein at least three of said plurality of spiral elements are physically coupled together via one or more of a plurality of articulated couplings, respectively, with a first articulated coupling disposed on a first side of a winding channel of a first spiral element and a second articulated coupling disposed on a second side of said winding channel of said first spiral element.
[5]
The inductive device of claim 1, wherein each of said spiral elements comprises a pair of flanges with a winding spool disposed substantially therebetween, said conductive winding wound on said winding spool.
[6]
The inductive device of claim 5, wherein said spiral elements have one or more terminals comprising self-conducting terminals incorporated in at least one side wall of at least one of said pair of flanges.
[7]
The inductive device of claim 1, wherein said plurality of spiral elements comprises three or more spiral elements, with a starting and a ending portion of said conductive winding being disposed at one of said non-ends. three or more spiral elements
[8]
The inductive device of claim 1, wherein the conductor winding comprises a plurality of layers disposed on one or more winding cylinders of said spiral elements.
[9]
The inductive device of claim 8, wherein at least one of said layers comprises a shielding layer operative to at least mitigate transmission of electromagnetic noise during operation.
[10]
The inductive device of claim 9, at BR 15 wherein said plurality of layers comprises: two or more shield layers; and . one or more current sensing layers; wherein said two or more shielding layers and said one or more current sensing layers are interspersed with each other.
[11]
The inductive device of claim 1, wherein at least a portion of said spiral elements further comprises: . a pair of flanges; 25 . a winding channel disposed between said pair of flanges; - a plurality of conductive winding layers disposed in said winding channel and one or more hinge features.
[12]
The inductive device of claim 11 further comprising a housing comprising a conductor receiving aperture.
[13]
An inductive device according to claim 12, in | that said plurality of spiral elements are collectively arranged around said conductor receiving opening in a substantially alternating or zigzag fashion.
[14]
The inductive device of claim 11, wherein at least one said plurality of layers of windings comprise a shielding layer.
[15]
The inductive device of claim 14, wherein the winding direction for said shield layer alternates between adjacently disposed, linearly wound inductive devices,
[16]
The inductive device of claim 12 wherein said conductor receiving opening includes an integrated conductor which is to be detected by said spiral elements.
[17]
The inductive device of claim 12 at . 15 that said housing further comprises a plurality of terminals for electrical interfacing with a printed circuit board.
[18]
. The inductive device of claim 12, wherein said housing includes a plurality of alignment features disposing said spiral elements in a substantially alternate or zigzag fashion when said spiral elements - rais are received in it.
[19]
19, A method of manufacturing an inductive current sensing device, comprising: . attaching a first end and a winding conducting one of a plurality of segmented winding elements; . continuously winding said conductive winding onto said plurality of segmented winding elements in a sequential order; and . securing said second end of said conductive winding to one of the plurality of segmented winding elements.
[20]
The method of claim 19, wherein said | first end and said second end of said attached conductive winding are secured thereto of said plurality of segmented winding elements.
[21]
The method of claim 20, wherein said sequential order comprises: . traversing a median of said plurality of segmented winding elements to a first end segmented winding element of said plurality of winding elements - segmented ment; 10 . traversing said first end segmented winding element of said plurality of segmented winding elements to a second end segmented winding element of said plurality of segmented winding elements; and . 15 . traversing said second end segmented winding element of said plurality of winding elements. are segmented back to said intermediate of said plurality of segmented winding elements.
[22]
The method of claim 19, wherein said act of attaching said first end comprises terminating said conductive winding on a self-conducting terminal present on said one of the plurality of segmented winding elements.
|
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法律状态:
2021-04-27| B08F| Application fees: application dismissed [chapter 8.6 patent gazette]|Free format text: REFERENTE A 10A ANUIDADE. |

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2021-08-17| B08K| Patent lapsed as no evidence of payment of the annual fee has been furnished to inpi [chapter 8.11 patent gazette]|Free format text: EM VIRTUDE DO ARQUIVAMENTO PUBLICADO NA RPI 2625 DE 27-04-2021 E CONSIDERANDO AUSENCIA DE MANIFESTACAO DENTRO DOS PRAZOS LEGAIS, INFORMO QUE CABE SER MANTIDO O ARQUIVAMENTO DO PEDIDO DE PATENTE, CONFORME O DISPOSTO NO ARTIGO 12, DA RESOLUCAO 113/2013. |

优先权:

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申请号 | 申请日 | 专利标题

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US12/684,056|US9823274B2|2009-07-31|2010-01-07|Current sensing inductive devices|

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US12/2684,056|2010-01-07|

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US12/954,546|2010-11-24|

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US12/954,546|US9151782B2|2009-07-31|2010-11-24|Current sensing devices and methods|

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PCT/US2011/020397|WO2011097045A1|2010-01-07|2011-01-06|Current sensing devices and methods|

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