WO2006086045A2 - Precision rogowski coil and method for manufacturing same - Google Patents
Precision rogowski coil and method for manufacturing same Download PDFInfo
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- WO2006086045A2 WO2006086045A2 PCT/US2005/043164 US2005043164W WO2006086045A2 WO 2006086045 A2 WO2006086045 A2 WO 2006086045A2 US 2005043164 W US2005043164 W US 2005043164W WO 2006086045 A2 WO2006086045 A2 WO 2006086045A2
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- WIPO (PCT)
- Prior art keywords
- coil
- core
- grooving
- winding
- return
- Prior art date
Links
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- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 238000004804 winding Methods 0.000 claims abstract description 45
- 239000000463 material Substances 0.000 claims abstract description 12
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/003—Printed circuit coils
-
- 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
- G01R15/181—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks using inductive devices, e.g. transformers using coils without a magnetic core, e.g. Rogowski coils
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/0006—Printed inductances
- H01F17/0033—Printed inductances with the coil helically wound around a magnetic core
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F21/00—Variable inductances or transformers of the signal type
- H01F21/12—Variable inductances or transformers of the signal type discontinuously variable, e.g. tapped
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/40—Structural association with built-in electric component, e.g. fuse
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
Definitions
- the present invention concerns Rogowski coils . More particularly, the present invention concerns the structure and manner of making a Rogowski coil .
- Rogowski coils are well known electrical devices finding use today for measurement of magnetic fields and electrical currents . They have been researched over the past century and are well known to the scientific literature. Their origin traces to the invention circa 1912 of the Rogowski coil by W. Rogowski and W. Steinhousen. The device is useful for measuring electrical currents and operates on the basis of a magnetic field integration performed across a closed contour being equal to the current flowing through the contour.
- the coil provides a voltage output proportional ⁇ o the time derivative of the current (di/dt) output like other current transformers .
- Rogowski coils are popular because of their dynamic range and linearity. However, though theoretical requirements are known, manufacturers still need ways to provide a high quality coil that is both economical to manufacture and which is satisfactory for precise current measurements .
- the device (coil) should be insensitive to external influences, insensitive to the measured primary conductor position, and retain high precision (in the order of 0.3% or better) over its lifetime and across a wide temperature range (nominally -40 to 70 degrees Centigrade ) .
- U . S . Patent 5, 414 , 400 entitled “Rogowski Coil” discloses a Rogowski coil made on a printed circuit plate provided with a circular cut-out .
- the coil is implemented by metal deposits on each of the two faces of the plate extending along radii, with electrical connections between the radii on one face and those on the opposite face being achieved via plated-through holes passing through the thickness of the plate .
- U . S . Patent 5 , 442 , 280 discloses a method for manufacturing a printed circuit board-based Rogowski coil .
- the disclosed geometry provides very high turn density resulting in very high sensitivity. While high sensitivity is very desirable when measuring low frequency currents ( 50/60Hz power system related) , the patent fails to provide adequate means for external field cancellation . This problem is reported in U . S . Patent 6, 624 , 624 and is caused by inadequate handling of the coil return path .
- Patent 6, 300, 857 for "Insulating Toroid Cores and Windings” discloses a configuration to improve the winding of precise conventional transformer coils and includes an insulating j acket around a magnetic core .
- the insulating j acket includes plural protrusions around the core, the protrusions demarking various segments of the toroid.
- the toroid may be divided into six evenly spaced sections , each occupying approximately 60° . At the edges of each section, there is a protrusion . The protrusions maintain the placement and spacing of windings within each section.
- An obj ect of the present invention is to provide a precision Rogowski coil with its winding geometry defined and controlled at the time of manufacture, with improved dimensional stability maintained throughout its lifetime .
- a precision Rogowski coil includes a generally toroidal (or toroid-like) core having grooving thereon in which to register the wire ( or other conductive material) turns of a main coil .
- the core is made of a moldable material having grooves therein in a pattern corresponding to the main coil winding .
- the grooves are helical, and the coil wire or conductor fits into the grooves on the core .
- a conductor other than wire can be used, such as a deposited conductor .
- a return path or reverse winding are also provided, and various structures and methods address return path cancellation and thermal and other variations .
- Invented manufacturing techniques include molding a core having grooving on its exterior and then winding wire in the grooving or otherwise forming a conductive winding using the grooving to control the location of the winding on the core .
- Figure IA is a diagram of a top view of a toroidal coil core, prior to winding wire thereon, with some of the grooving shown, and embodying various aspects of the present invention
- Figure IB is a diagrammatic side view of the core of
- FIGs . 2A and 2B are sketches of two alternate constructions of the core with representative constant pitch helical winding wound thereon using a circumferential loop for return path cancellation;
- FIG. 3 is an electrical circuit diagram of a resistive network applicable to Rogowski coils of the present invention for effective return path diameter (radius ) compensation;
- Figs . 4A and 4B represent another embodiment of a toroidal core with modified grooving, forming a Rogowski coil having a winding that is radial on three sides of the toroid with coil advancement restricted to the forth (outer) side; [0019] Fig .
- FIG. 5 represents an alternate construction of a toroidal core embodying aspects of the present invention
- Fig. 6 is used in describing an alternate coil manufacturing method in which the grooved toroidal core is used as a substrate for conductive material being deposited within the grooves ;
- Fig . 7 is an electrical circuit diagram of a resistive network applicable to Rogowski coils of the present invention for temperature and gain compensation;
- Fig . 8 represents another embodiment of the current invention in which the grooves are used to support a second coil wound on top of the first coil, but with an opposite direction of coil advancement .
- Figure IA illustrates a core 10 shaped generally as a toroid.
- the term “toroid” often connotes a “doughnut” shape but the present invention does not require a “doughnut” shape for the core 10.
- a cross section cut through a diameter or radius of core 10 can be either circular, substantially rectangular, or otherwise, e . g . oval , oblong, or some other shape .
- core 10 may have the geometric shape of a solid formed by rotating (orbiting) a closed form, be it a circle, square, rectangle, oval, oblong, or irregular shaped closed line, around 360 degrees of a circle .
- FIG. 2A shows a Rogowski coil according to certain aspects of the present invention where the core has generally "flattened” faces ( like an annulus) , which (but for the grooving) could be formed geometrically by rotating a rectangle with rounded corners around 360 degrees of a circle .
- FIG. 2B shows another core according to aspects of the present invention, where the faces are not flattened but instead are rounded with a circular cross section ( somewhat like an 0-ring) . That geometric form (again, without the grooving) could be obtained by rotating a circle around 360 degrees of a larger circle .
- the term "toroid” as used herein is used in a broad context and is intended to embrace all such geometries .
- Core 10 may vary widely in dimensions, illustratively on the order of 0.25 inch in outside diameter (or less ) to eighteen or twenty inches , or more .
- core 10 comprises a non ferro-magnetic, electrical insulator, preferably one with a minimal coefficient of thermal expansion, and more preferably a moldable polymeric material .
- core 10 may be made of Thermoset Polyester with thermal expansion coefficient in the order of 9ppm/°c, glass reinforced thermoplastic polyester PET ( 36ppm/°c) , glass reinforced epoxy
- Core 10 is patterned with precision grooves 12 around its exterior .
- Figure IA illustrates the patterning in a small continuous section, it is to be understood that the patterning extends, in the preferred embodiment, around the full 360 ° (2 ⁇ radians) as shown in Figures 2A, 2B, 4A, 4B, 5 , 6 and 8.
- groove 12 is a single, continuous helical groove as shown in Figure 2B .
- the groove pattern may be molded with uniform, predetermined characteristics so that each core 10 made from the mold has precisely the same shape and the same precision grooving .
- groove 12 could be placed on the core by a machine process .
- grooving 12 has a uniform pitch around the toroid.
- the dimensions of grooving i . e . , its width and depth
- the magnet wire used for the coil and return path conductor can be wound on the toroidal core in well- known fashion using well-known equipment for this task.
- the coil may comprise a large number of turns , illustratively 1000 turns, although no upper or lower limitation in the number of turns is implied .
- the wire of the main coil seats in the grooves 12. That is, with respect to Fig.
- wire may be wound around the toroid so that it "enters the page” on the outside of the core 10 and “comes out of the page” in the central opening of the toroid, or vice versa .
- the coil geometry is defined and controlled at the outset , and the resulting Rogowski coil will be dimensionally stable throughout its lifetime .
- a varnish based coating can be added to further stabilize the coil .
- Return path cancellation can be achieved in various ways .
- One way is to provide a return loop .
- a circumferential groove 14 may be machined, molded, or otherwise provided around the outside edge of core 10 , as seen in Fig . IB .
- a return loop 16 can be positioned in such groove 14.
- the return path (return loop 16) is to null out, to the extent possible, the effect of the coil wound about the toroid.
- return loop 16 must be wound in the counterclockwise direction, or vice versa .
- the return loop is wound around the circumference first , and then the coil is wound over toroid on which the return path conductor is already in place .
- FIG. 2A is a view of a Rogowski coil, which comprises main wire turns 18 and the return loop 16. Electrically, the coil has points 1, 2 , and 3. Point 1 is the end of the return loop 16. Point 2 is the beginning of the main coil 18. Point 3 represents the point at which the main coil 18 connects to the return loop 16.
- the main coil 18 will have an effective advancement path radius represented by rl in Figure IA.
- effective advancement path ri will be positioned within the coil, half way between the inner radius ri and the outer radius r o of the coil .
- Return loop 16 is located generally at the outer edge of the core 10, except it sits within groove 14 so that its actual radius is slightly less than the maximum radius of the toroid .
- r2 denotes the actual radius of the return loop 16.
- the return loop radius r2 is generally larger than effective radius rl with the result that return path cancellation is suboptimal .
- Other parameters namely the z-axis position and concentricity of the two paths ("front" and "back” of the toroid) are well matched, making it possible to use a passive circuit based technique for return path effective diameter (radius ) adj ustment .
- the return coil By advantageously positioning the return coil on the outside of the effective advancement path radius ri of the main coil (r 2 >ri) , it is possible to ensure that Victual > Vo es -j_ re d making it possible to use a simple resistive divider (highly reliable passive network) to match exactly the desired compensation path output to the actual output of the coil advancement path .
- the resistive divider is ' used to effectively reduce radius r 2 with the obj ective of matching it to the radius ri .
- Equation (2 ) above describes the matched state relationship .
- Simple algebraic manipulations allow equations ( 1 ) and (2 ) to be used to determine the ratiometric relation between gain matching resistors Rl and R2. The final relation is given in equation ( 3 ) . It will be understood that by changing the coil geometry (thus affecting the effective radii ri and r 2 by making ri>r 2 ) , it may become necessary to attenuate the output of the main coil instead of the return path output . Such modification is anticipated and does not deviate from, the spirit of this invention .
- the exact value of matching resistors is less significant than their ratio, with typical values ranging between 1 and 1000 ohms . If advantageous , the resistor value can be selected to match the attached transmission line impedance . The resistor value should be kept below 1000 ohms to reduce the resistor-generated noise contribution .
- the resistive network can be placed in close proximity of the coil, by soldering resistors Rl and R2 directly to the return (compensation) coil output . If required, a separate set of conductors can be used to bring both the output of the main coil and the return coil to a remote location (up to 100m) equipped with resistors Rl and R2. [0033] Referring to Fig .
- a modification of this first approach for cancellation is to provide essentially radial grooves 12 at first locations 21 (upper face) , 22 (inside face) , and 23 (lower face) of the toroid, and to provide sequential non-radial grooving 12a (see Fig. 4B) at second locations 24 radially outward of the radial grooving, thereby to concentrate the coil advancement at the second locations 24.
- the second locations 24 are located toward or on the outside edge of the toroid core 10.
- the grooves 12a are not radial, but are pitched 32, and remain symmetrical .
- radius rl is increased and can be brought very close to the return loop radius r2 , thus alleviating (and in less demanding applications , totally eliminating) the need for resistor based compensation .
- a third technique for return path cancellation is to provide, instead of the single loop 16 in groove 14, a second layer of winding, that is, a return winding, with a constant pitch adjusted to avoid physical interference between the two layers .
- the pitch of the second winding layer need not match the winding pitch of the first layer and can conveniently be reduced to as little as ten turns , illustratively. Further reduction lower than ten turns is counterproductive due to the potential for increased sensitivity to the measured conductor position .
- a return winding is made on top or next to the first one, but in the opposite direction of coil advancement .
- Figure 8 One embodiment of this invention is shown in Figure 8. The windings are assumed to cover the entire circumference of the toroid, as indicated by the arrows in the figure .
- a high quality coil can be manufactured economically and still be essentially insensitive to external influences, insensitive to measured primary conductor position, and will retain high precision on the order of 0.3% over its lifetime across a wide operating temperature range , illustratively from -40 °C to 70 0 C .
- the core need not be thermoplastic material but can be an insulator manufactured according to any known technology such as molding, machining, and other forms of manufacturing well known in that art .
- temperature and gain compensation techniques are applicable to the precision wound toroid according to the present invention . Return path cancellation as set forth above is used to compensate for the effect of coil advancement .
- such compensation can be achieved by adding a thermally sensitive compensation resistor (R3 ) and combining it with a temperature stable resistor (R4 ) .
- resistors R3 and R4 form a temperature compensating divider, which is added to the main coil output .
- Gain compensation is normally performed during coil manufacturing (factory calibration) by trimming one or both legs of the output divider . Individual coil gain is determined by passing known electrical current through the coil opening, and recording the voltage present at the coil output, or by comparing the coil output with a known calibration artifact .
- grooves 12 need not extend in a single helical pattern around core 10.
- the grooves 12 could be segmented as desired, illustratively providing left and right segments each occupying substantially 180° of arc, or three segments each having substantially 120 ° of arc, or four segments having 90° of arc each, and so forth.
- the grooves 12 extend substantially continuously around the toroidal core 10 in helical fashion .
- One discontinuity already occurs where groove 12 intercepts the circumferential groove 14.
- further discontinuities could be allowed, with groove being essentially reduced to simple notches positioned at the four edges of the toroid.
- grooving may extend around 360° of arc of the coil (in the plane represented in Figure 1) , a variation may truncate the grooving .
- Figure 5 shows one such variation wherein grooves 12 are discontinuous but nevertheless aligned in the helical or other patterns described herein.
- Grooves 12 may, illustratively, comprise first portions 40 located on the face of the toroid, second portions located around an outside perimeter (not shown in Fig. 5 ) , third portions located around an inside perimeter (not shown in Fig . 5 ) , and fourth portions 42 located on the opposite face of the toroidal coil 10.
- the main coil can be manufactured by using conductive material deposited into the grooves of the toroid.
- This approach requires three steps : manufacturing of the grooved toroid, application of the conductive layer covering the entire surface of the toroid, and removal of the conductive material from the elevated ridges, thus forming the coil by leaving only the conductive material within the grooves .
- This approach is illustrated in Figure 6 wherein the entire surface of the grooved toroid 10 is made conductive using electrochemical deposition (electroplating) , vacuum deposition, or by extruding conductive polymer into the grooves 12.
- the coil is formed by subsequently machining ( sanding, grinding) the outside surfaces of the toroid, thus forming the insulated ridges 60 in between the individual loops of the main coil 12.
- the return coil is realized in accordance with the previous descriptions and is not shown in Figure 6.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Coils Or Transformers For Communication (AREA)
- Transformers For Measuring Instruments (AREA)
- Measuring Instrument Details And Bridges, And Automatic Balancing Devices (AREA)
Abstract
Description
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Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002595490A CA2595490A1 (en) | 2005-02-04 | 2005-11-30 | Precision rogowski coil and method for manufacturing same |
BRPI0519873-9A BRPI0519873A2 (en) | 2005-02-04 | 2005-11-30 | coil and method to manufacture a coil |
EP05852426A EP1844481A2 (en) | 2005-02-04 | 2005-11-30 | Precision rogowski coil and method for manufacturing same |
AU2005327088A AU2005327088A1 (en) | 2005-02-04 | 2005-11-30 | Precision rogowski coil and method for manufacturing same |
NZ556468A NZ556468A (en) | 2005-02-04 | 2005-11-30 | Precision rogowski coil and method for manufacturing same |
MX2007009391A MX2007009391A (en) | 2005-02-04 | 2005-11-30 | Precision rogowski coil and method for manufacturing same. |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/051,232 US7227441B2 (en) | 2005-02-04 | 2005-02-04 | Precision Rogowski coil and method for manufacturing same |
US11/051,232 | 2005-02-04 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2006086045A2 true WO2006086045A2 (en) | 2006-08-17 |
WO2006086045A3 WO2006086045A3 (en) | 2006-12-21 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2005/043164 WO2006086045A2 (en) | 2005-02-04 | 2005-11-30 | Precision rogowski coil and method for manufacturing same |
Country Status (8)
Country | Link |
---|---|
US (2) | US7227441B2 (en) |
EP (1) | EP1844481A2 (en) |
AU (1) | AU2005327088A1 (en) |
BR (1) | BRPI0519873A2 (en) |
CA (1) | CA2595490A1 (en) |
MX (1) | MX2007009391A (en) |
NZ (1) | NZ556468A (en) |
WO (1) | WO2006086045A2 (en) |
Cited By (1)
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AT525335A1 (en) * | 2021-07-21 | 2023-02-15 | Egston System Electronics Eggenburg Gmbh | CURRENT SENSOR COIL ARRANGEMENT |
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US8872611B2 (en) | 2011-08-18 | 2014-10-28 | General Electric Company | Rogowski coil assemblies and methods for providing the same |
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US8829888B2 (en) | 2011-09-09 | 2014-09-09 | General Electric Company | Sensor devices and methods for use in sensing current through a conductor |
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- 2005-11-30 BR BRPI0519873-9A patent/BRPI0519873A2/en not_active IP Right Cessation
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Also Published As
Publication number | Publication date |
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EP1844481A2 (en) | 2007-10-17 |
AU2005327088A1 (en) | 2006-08-17 |
US20070226989A1 (en) | 2007-10-04 |
NZ556468A (en) | 2010-10-29 |
CA2595490A1 (en) | 2006-08-17 |
BRPI0519873A2 (en) | 2009-08-04 |
MX2007009391A (en) | 2007-09-21 |
US7474192B2 (en) | 2009-01-06 |
US20060176140A1 (en) | 2006-08-10 |
US7227441B2 (en) | 2007-06-05 |
WO2006086045A3 (en) | 2006-12-21 |
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