WO2001040812A2 - Current sensor and method of manufacturing same - Google Patents

Current sensor and method of manufacturing same Download PDF

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Publication number
WO2001040812A2
WO2001040812A2 PCT/EP2000/011764 EP0011764W WO0140812A2 WO 2001040812 A2 WO2001040812 A2 WO 2001040812A2 EP 0011764 W EP0011764 W EP 0011764W WO 0140812 A2 WO0140812 A2 WO 0140812A2
Authority
WO
WIPO (PCT)
Prior art keywords
primary
pin header
magnetic circuit
current
conductors
Prior art date
Application number
PCT/EP2000/011764
Other languages
French (fr)
Other versions
WO2001040812A3 (en
Inventor
Kenneth Mcintosh Govan
Original Assignee
Honeywell Control Systems Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Honeywell Control Systems Ltd. filed Critical Honeywell Control Systems Ltd.
Priority to AU26684/01A priority Critical patent/AU2668401A/en
Publication of WO2001040812A2 publication Critical patent/WO2001040812A2/en
Publication of WO2001040812A3 publication Critical patent/WO2001040812A3/en

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R15/00—Details of measuring arrangements of the types provided for in groups G01R17/00 - G01R29/00, G01R33/00 - G01R33/26 or G01R35/00
    • G01R15/14—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks
    • G01R15/18—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks using inductive devices, e.g. transformers
    • G01R15/183—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks using inductive devices, e.g. transformers using transformers with a magnetic core
    • G01R15/185—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks using inductive devices, e.g. transformers using transformers with a magnetic core with compensation or feedback windings or interacting coils, e.g. 0-flux sensors

Definitions

  • the present invention relates in general to the field of current sensors and more particularly to current sensors intended for mounting on printed circuit boards (PCBs) and a method of manufacturing the same.
  • a common means for measuring electrical current is a null balance current sensor.
  • This type of sensor comprises a laminated core through which there passes a primary conductor that carries the current which is to be measured and which therefore induces a proportional magnetic field in the magnetic core.
  • Around the magnetic core there are also provided secondary windings through which a balance current is passed that produces a magnetic field configured to oppose and cancel out that due to the primary conductor.
  • the balance current is maintained at the correct value to maintain the net magnetic field in the core at zero by using negative feedback and a magnetic flux sensor.
  • the magnetic flux sensor might be a Hall Effect sensor positioned in an air gap in the laminations .
  • the output value for the current measured is derived from the balance current.
  • Such sensors may have more than one primary conductor in order to make them more flexible to use. For example, a large current might be split between several primary conductors in order to avoid overloading them. When there are multiple primary conductors there is a risk that there would be leakage of current between them, affecting not only the accuracy of the measurement but also the signal which is to be measured.
  • a further aim of the present invention is to devise a means for having multiple primary conductors in which the primary conductors are effectively insulated from each other.
  • US Patent No 5,004,974 to Liasons Electroniques Mecaniqu describes a current sensor which goes some way towards fulfilling the above aims.
  • null balance current sensors are bulk manufactured in a variety of sizes and current ranges.
  • a further aim of the present invention is to provide a more cost-effective means of manufacturing current sensors whilst still fulfilling the aims described above. Furthermore, it is an aim to provide a cost-effective means of producing a range of current sensors with different properties such as size, measurement range etc.
  • a current measuring device for measuring a current supplied thereto, the device comprising a magnetic circuit and a primary pin header, the primary pin header comprising an insulated pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulated pin header block and two end portions which are arranged for connection to an external circuit board, wherein the insulated pin header block and the middle portion of the or each primary conductor embedded therein partially surrounding a section of the said magnetic circuit .
  • the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes .
  • the primary pin header comprises at least one clip for mounting the primary pin header within the device. More preferably, the or each primary conductor is substantially U-shaped.
  • a method of manufacturing a current measuring device for measuring a current supplied thereto comprising the steps of: a) manufacturing a current measuring device body comprising a magnetic circuit receiving means,- b) fitting a magnetic circuit into the magnetic circuit receiving means,- and c) fitting a primary pin header comprising an insulated pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulated pin header block and two end portions which are arranged for connection to an external circuit board, such that the insulated pin header block and the middle portion of the or each primary conductor embedded therein partially surround a section of the said magnetic circuit, either surrounding secondary windings or laminations .
  • the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes .
  • a method of manufacturing a current measuring device for measuring a current supplied thereto comprising the steps of: a) manufacturing a current measuring device body comprising a magnetic circuit receiving means,- b) attaching to the current measuring device body a primary pin header, the primary pin header comprising an insulating pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulating pin header block and two end portions which are arranged for connection to an external circuit board; and c) fitting a magnetic circuit into the magnetic circuit receiving means such that the magnetic circuit is partially surrounded by the insulating pin header block and the middle portion of the or each primary conductor embedded therein either surrounding secondary windings or laminations .
  • the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes .
  • the magnetic circuit comprises a plurality of independently fitted laminations.
  • Figure 1 is an exploded view of a current sensor
  • Figure 2 is a perspective view of a primary pin header
  • Figure 3 is a side view of a primary pin header
  • Figure 4 is a plan view from underneath of a primary pi " header
  • Figure 5 is a cross -section through an indi idual conductor member .
  • Figure 1 is an exploded view of a current sensor 1, designed for mounting on a PCB, as provided by the present invention.
  • the body of the current sensor comprises an internal PCB 2 to which are fixed electronic components required for the functionalicy of the device e.g. 3, 4.
  • a conventional input/output pin header 5 is mounted on the internal PCB 2 and holds pins 6 which are spaced correctly to be soldered onto a PCB and which conduct the power supply (two pins) and output current (one pin) .
  • a laminated magnetic core 7 Indirectly attached to the internal PCB 2 is a laminated magnetic core 7. This is held in place at one side by a bobbin moulding 9 with flanges 8 and 10 which also act to hold in place the secondary windings 11.
  • the secondary windings 11 are connected to the internal PCB by through- pins 12.
  • a current sensor such as a Hall Sensor is provided in mounting 9.
  • the primary conductor is part of a primary pin header 20.
  • the primary pin header 20 is shown in perspective view in Figure 2, side view in Figure 3 and in plan view from underneath in Figure 4.
  • the primary pin header comprises a plurality of primary conductors 21, embedded in a plastic overmoulding 22 which has clips 23, 24, 25 for fitting into place in the body of the device.
  • the primary conductors 21 are shaped to be readily fitted into an external PCB.
  • the provision of the overmoulding provides improved creepage and clearance between the primary conductors and the internal PCB. By effectively insulating the primary conductors 21 from each other, current leakage is eliminated.
  • the overmoulding also allows an accurate relationship: to be maintained between the primary conductors 21.
  • Individual primary conductors 21 are U-shaped as shown in cross-section in Figure 5 and the pin header shown consists of four conductor members.
  • the primary pin header 20 can be fitted in place before or after the laminations that comprise the magnetic core have been fitted into place in the coil assembly 8, 9, 10, 11.
  • the device is inserted into a cover 30 and potted, providing a convenient, PCB mounting current sensor that can economically be manufactured in a series of current ranges.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Measuring Instrument Details And Bridges, And Automatic Balancing Devices (AREA)

Abstract

A current sensor (1) and methods of making a current sensor suitable for mounting on a printed circuit board. A primary pin header (20) is provided which contains the primary conductors (21) embedded in an insulating block (22). The primary pin header (20) can be manufactured independently of the rest of the sensor (1) and fitted before or after the laminated magnetic core (7). This allows a range of sensors to be manufactured by varying only the primary pin header (20).

Description

CURRENT SENSOR AND METHOD OF MANUFACTURING SAME The present invention relates in general to the field of current sensors and more particularly to current sensors intended for mounting on printed circuit boards (PCBs) and a method of manufacturing the same. A common means for measuring electrical current is a null balance current sensor. This type of sensor comprises a laminated core through which there passes a primary conductor that carries the current which is to be measured and which therefore induces a proportional magnetic field in the magnetic core. Around the magnetic core there are also provided secondary windings through which a balance current is passed that produces a magnetic field configured to oppose and cancel out that due to the primary conductor. The balance current is maintained at the correct value to maintain the net magnetic field in the core at zero by using negative feedback and a magnetic flux sensor. The magnetic flux sensor might be a Hall Effect sensor positioned in an air gap in the laminations . The output value for the current measured is derived from the balance current.
Current sensors are typically used as only one component of a more complex circuit. For this reason, it is desirable to be able to produce current sensors that could be readily mounted on standard PCBs. Conventional null balance current sensors which might be mounted on PCB5 have bus bars protruding from either side of the sensor for connecting the primary conductor to external devices . These give the sensors a large footprint and so are inconvenient to use . It is an aim of the present invention to provide a null balance current sensor which has a small footprint, is convenient to mount on a PCB and is manufactured within tolerances appropriate for use with PCBs.
Such sensors may have more than one primary conductor in order to make them more flexible to use. For example, a large current might be split between several primary conductors in order to avoid overloading them. When there are multiple primary conductors there is a risk that there would be leakage of current between them, affecting not only the accuracy of the measurement but also the signal which is to be measured. A further aim of the present invention is to devise a means for having multiple primary conductors in which the primary conductors are effectively insulated from each other. US Patent No 5,004,974 to Liasons Electroniques Mecaniqu describes a current sensor which goes some way towards fulfilling the above aims. However, null balance current sensors are bulk manufactured in a variety of sizes and current ranges. Current sensors are sold into a competitive marketplace and so methods of making the devices more economically are of great commercial value. Therefore, a further aim of the present invention is to provide a more cost-effective means of manufacturing current sensors whilst still fulfilling the aims described above. Furthermore, it is an aim to provide a cost-effective means of producing a range of current sensors with different properties such as size, measurement range etc.
According to the present invention there is provided a current measuring device for measuring a current supplied thereto, the device comprising a magnetic circuit and a primary pin header, the primary pin header comprising an insulated pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulated pin header block and two end portions which are arranged for connection to an external circuit board, wherein the insulated pin header block and the middle portion of the or each primary conductor embedded therein partially surrounding a section of the said magnetic circuit .
Preferably, the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes .
Preferably also, the primary pin header comprises at least one clip for mounting the primary pin header within the device. More preferably, the or each primary conductor is substantially U-shaped.
According to a second aspect of the present invention there is provided a method of manufacturing a current measuring device for measuring a current supplied thereto, the method comprising the steps of: a) manufacturing a current measuring device body comprising a magnetic circuit receiving means,- b) fitting a magnetic circuit into the magnetic circuit receiving means,- and c) fitting a primary pin header comprising an insulated pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulated pin header block and two end portions which are arranged for connection to an external circuit board, such that the insulated pin header block and the middle portion of the or each primary conductor embedded therein partially surround a section of the said magnetic circuit, either surrounding secondary windings or laminations .
Preferably, the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes .
According to a third aspect of the present invention, there is provided a method of manufacturing a current measuring device for measuring a current supplied thereto, the method comprising the steps of: a) manufacturing a current measuring device body comprising a magnetic circuit receiving means,- b) attaching to the current measuring device body a primary pin header, the primary pin header comprising an insulating pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulating pin header block and two end portions which are arranged for connection to an external circuit board; and c) fitting a magnetic circuit into the magnetic circuit receiving means such that the magnetic circuit is partially surrounded by the insulating pin header block and the middle portion of the or each primary conductor embedded therein either surrounding secondary windings or laminations .
Preferably, the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes .
More preferably, the magnetic circuit comprises a plurality of independently fitted laminations. An example of the present invention will now be described with reference to the following Figures in which:
Figure 1 is an exploded view of a current sensor; Figure 2 is a perspective view of a primary pin header,- Figure 3 is a side view of a primary pin header;
Figure 4 is a plan view from underneath of a primary pi " header; and
Figure 5 is a cross -section through an indi idual conductor member .
Figure 1 is an exploded view of a current sensor 1, designed for mounting on a PCB, as provided by the present invention. The body of the current sensor comprises an internal PCB 2 to which are fixed electronic components required for the functionalicy of the device e.g. 3, 4. A conventional input/output pin header 5 is mounted on the internal PCB 2 and holds pins 6 which are spaced correctly to be soldered onto a PCB and which conduct the power supply (two pins) and output current (one pin) .
Indirectly attached to the internal PCB 2 is a laminated magnetic core 7. This is held in place at one side by a bobbin moulding 9 with flanges 8 and 10 which also act to hold in place the secondary windings 11. The secondary windings 11 are connected to the internal PCB by through- pins 12. A current sensor such as a Hall Sensor is provided in mounting 9.
The primary conductor is part of a primary pin header 20.
The primary pin header 20 is shown in perspective view in Figure 2, side view in Figure 3 and in plan view from underneath in Figure 4.
The primary pin header comprises a plurality of primary conductors 21, embedded in a plastic overmoulding 22 which has clips 23, 24, 25 for fitting into place in the body of the device. The primary conductors 21 are shaped to be readily fitted into an external PCB. Importantly, the provision of the overmoulding provides improved creepage and clearance between the primary conductors and the internal PCB. By effectively insulating the primary conductors 21 from each other, current leakage is eliminated. The overmoulding also allows an accurate relationship: to be maintained between the primary conductors 21. Individual primary conductors 21 are U-shaped as shown in cross-section in Figure 5 and the pin header shown consists of four conductor members. The primary pin header 20 can be fitted in place before or after the laminations that comprise the magnetic core have been fitted into place in the coil assembly 8, 9, 10, 11.
This means that a range of current sensors with different measuring ranges can be readily and economically made by manufacturing all parts of the sensor other than the primary pin header 20 in bulk and then substituting different primary pin headers with, for example, different pin sizes appropriate to different measuring ranges.
Once a primary pin header 20 has been fitted, the device is inserted into a cover 30 and potted, providing a convenient, PCB mounting current sensor that can economically be manufactured in a series of current ranges.
Further modifications and improvements may be incorporated without departing from the scope of the invention herein intended.

Claims

1. A current measuring device for measuring a current supplied thereto, the device comprising a magnetic circuit and a primary pin header, the primary pin header comprising an insulated pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulated pin header block and two end portions which are arranged for connection to an external circuit board, wherein the insulated pin header block and the middle portion of the or each primary conductor embedded therein partially surrounding a section of the said magnetic circuit .
2. An electric current sensing device as claimed in claim 1 wherein the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes .
3. An electric current sensing device as claimed in claim 1 or claim 2 wherein the primary pin header comprises at least one clip for mounting the primary pin header within the device.
4. An electric current sensing device as claimed in any preceding claim wherein the or each primary conductor is substantially U-shaped.
5. A method of manufacturing a current measuring device for measuring a current supplied thereto, the method comprising the steps of:
a) manufacturing a current measuring device body comprising a magnetic circuit receiving means,- b) fitting a magnetic circuit into the magnetic circuit receiving means,- and c) fitting a primary pin header comprising an insulated pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulated pin header block and two end portions which are arranged for connection to an external circuit board, such that the insulated pin header block and the middle portion of the or each primary conductor embedded therein partially surrounding a section of the said magnetic circuit either surrounded by secondary windings or laminations .
6. A method of manufacturing a current measuring device as claimed in claim 5 wherein the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes .
7. A method of manuf cturing a current measuring device for measuring a current supplied thereto, the method comprising the steps of: a) manufacturing a current measuring device body comprising a magnetic circuit receiving means; b) attaching to the current measuring device body a primary pin header, the primary pin header comprising an insulating pin header block and one or more primary conductors, the or each primary conductor comprising a middle portion which is embedded in the insulating pin header block and two end portions which are arranged for connection to an external circuit board; and c) fitting a magnetic circuit into the magnetic circuit receiving means such that the magnetic circuit is partially surrounded by the insulating a pin header block and the middle portion of the or each primary conductor embedded therein either surrounded by secondary windings or laminations.
8. A method of manufacturing an electric current sensing device as claimed in claim 7 wherein the primary pin header is selected from a group of primary pin headers, different members of the group of primary pin headers having primary conductors with different electrical properties and/or different shapes.
9. A method for manufacturing an electric current sensing device as claimed in claim 7 or claim 8 wherein the magnetic circuit comprises a plurality of independently fitted laminations.
PCT/EP2000/011764 1999-11-30 2000-11-25 Current sensor and method of manufacturing same WO2001040812A2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU26684/01A AU2668401A (en) 1999-11-30 2000-11-25 Current sensor and method of manufacturing same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB9928247.7A GB9928247D0 (en) 1999-11-30 1999-11-30 Current sensor and method of manufacturing same
GB9928247.7 1999-11-30

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WO2001040812A2 true WO2001040812A2 (en) 2001-06-07
WO2001040812A3 WO2001040812A3 (en) 2001-11-08

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1617228A1 (en) * 2004-07-16 2006-01-18 Liaisons Electroniques-Mecaniques Lem S.A. Current sensor
EP3086129A1 (en) * 2015-04-24 2016-10-26 Sumida Corporation Electric current detector
WO2017192256A1 (en) * 2016-05-04 2017-11-09 Safran Electrical & Power Busbar current sensor assembly
CN110031663A (en) * 2017-12-14 2019-07-19 泰连德国有限公司 The magnetic core with contact insertion hole with retention tab

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2538120A1 (en) * 1982-12-16 1984-06-22 Enertec Improvements to the construction of transformers with cancellation of magnetic flux
US5004974A (en) * 1989-05-30 1991-04-02 Liasons Electroniques-Mecaniques Electric current sensing device
EP0675368A1 (en) * 1994-03-30 1995-10-04 Landis & Gyr Technology Innovation AG Measuring instrument input circuit
US5552700A (en) * 1994-09-30 1996-09-03 Stanley Electric Co., Ltd. Current detecting device with a core having an integrally fixed engaging member
WO1999001773A1 (en) * 1997-07-04 1999-01-14 Liaisons Electroniques-Mecaniques Lem S.A. Electric current pick-up shoe

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2538120A1 (en) * 1982-12-16 1984-06-22 Enertec Improvements to the construction of transformers with cancellation of magnetic flux
US5004974A (en) * 1989-05-30 1991-04-02 Liasons Electroniques-Mecaniques Electric current sensing device
EP0675368A1 (en) * 1994-03-30 1995-10-04 Landis & Gyr Technology Innovation AG Measuring instrument input circuit
US5552700A (en) * 1994-09-30 1996-09-03 Stanley Electric Co., Ltd. Current detecting device with a core having an integrally fixed engaging member
WO1999001773A1 (en) * 1997-07-04 1999-01-14 Liaisons Electroniques-Mecaniques Lem S.A. Electric current pick-up shoe

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1617228A1 (en) * 2004-07-16 2006-01-18 Liaisons Electroniques-Mecaniques Lem S.A. Current sensor
WO2006008629A1 (en) * 2004-07-16 2006-01-26 Liaisons Electroniques-Mecaniques Lem S.A. Current sensor
EP1956378A1 (en) * 2004-07-16 2008-08-13 Liaisons Electroniques-Mecaniques Lem S.A. Current sensor
US7965162B2 (en) 2004-07-16 2011-06-21 Liaisons Electroniques-Mecaniques Lem S.A. Current sensor
EP3086129A1 (en) * 2015-04-24 2016-10-26 Sumida Corporation Electric current detector
US9939465B2 (en) 2015-04-24 2018-04-10 Sumida Corporation Electric current detector
WO2017192256A1 (en) * 2016-05-04 2017-11-09 Safran Electrical & Power Busbar current sensor assembly
US10782322B2 (en) 2016-05-04 2020-09-22 Safran Electrical & Power Busbar current sensor assembly
CN110031663A (en) * 2017-12-14 2019-07-19 泰连德国有限公司 The magnetic core with contact insertion hole with retention tab
CN110031663B (en) * 2017-12-14 2023-07-04 泰连德国有限公司 Magnetic core for conducting a magnetic field and assembly comprising a magnetic core

Also Published As

Publication number Publication date
GB9928247D0 (en) 2000-01-26
AU2668401A (en) 2001-06-12
WO2001040812A3 (en) 2001-11-08

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