Current sensing devices with integrated bus bars

• US 10,048,293 B2
• Filed: 04/04/2016
• Issued: 08/14/2018
• Est. Priority Date: 05/31/2012
• Status: Active Grant

• Current Assignee: Pulse Electronics Incorporated (Yageo Corporation)
• Original Assignee: Pulse Electronics Incorporated (Yageo Corporation)
• Inventors: Lint, James Douglas, Jin, Fuxue, Aldaco, Victor, Machado, Russell L.
• Primary Examiner(s): Nguyen, Vinh
• Application Number:
  US15/090,463
• Publication Number:
  US 20160291061A1
• Time in Patent Office: 862 Days
• CPC Class Codes: G01R 15/181 using coils without a magnetic core, e.g. Rogowski coils
• CPC Class Codes: G01R 31/28 Testing of electronic circuits, e.g. by signal tracer EMC, EMP or similar testing of electronic circuits G01R31/002; testing for short-circuits, discontinuities, leakage or incorrect line connection G01R31/50; checking computers or computer components G06F11/00; checking static stores for correct operation G11C29/00 ; testing receivers or transmitters of transmission systems H04B17/00
• CPC Class Codes: G06Q 30/04 Billing or invoicing
• CPC Class Codes: G06Q 50/06 Energy or water supply

Abstract

A low-cost and high-precision current sensing device and methods for use and manufacturing. In one embodiment, the current sensing apparatus comprises a Rogowski-type coil which is manufactured in segments so as to facilitate the manufacturing process. In an exemplary embodiment, the current sensing apparatus segments are asymmetric in shape and/or composition (e.g., bobbin shape, size, and/or winding configuration) so as to account for asymmetries in the magnetic field distribution around a bus bar, or to accommodate its shape in a more compact form factor, and/or to improve the immunity to the effects of an external magnetic field. Methods of manufacturing and using the aforementioned current sensing apparatus are also disclosed.

Claims

1. A current sensing device, comprising:

a plurality of sensing elements, one of the sensing elements comprising a plurality of terminals;

a bus bar element comprising two terminal ends, the plurality of sensing elements collectively being positioned about a portion of the bus bar element; and

a base element that receives a portion of the plurality of sensing elements, the base element further having a plurality of apertures disposed therein;

wherein the plurality of terminals of the one of the sensing elements and the two terminal ends of the bus bar element are configured to be received within respective ones of the plurality of apertures of the base element such that a portion of the plurality of terminals of the one of the sensing elements and the two terminal ends of the bus bar element each protrude from a bottom surface of the base element.

2. The current sensing device of claim 1, wherein each of the plurality of sensing elements comprises a wound bobbin, the wound bobbin including a spool portion disposed between two flange portions, the spool portion comprising an inner diameter and an outer diameter configured receive a plurality of turns of a conductive wire.

3. The current sensing device of claim 2, wherein the base element further comprises a first post feature, the first post feature configured to receive at least one of the sensing elements.

4. The current sensing device of claim 3, wherein the base element further comprises a second post feature, the second post feature configured to receive at least one of the sensing elements.

5. The current sensing device of claim 4, wherein the base element further comprises a space between the first and second post features, the space sized to accommodate at least one of the sensing elements.

6. The current sensing device of claim 3, wherein the first post feature comprises an at least partially cylindrical feature, a diameter of the at least partially cylindrical feature being less than the inner diameter of the spool portion of the wound bobbin.

7. The current sensing device of claim 2, wherein the wound bobbins further comprise a hinging feature, the hinging feature configured to facilitate articulation of at least a portion of the plurality of sensing elements around the bus bar element.

8. The current sensing device of claim 1, further comprising a cover element that is configured to be disposed over the plurality of sensing elements, at least portions of the bus bar element, and at least portions of the base element.

9. The current sensing device of claim 1, wherein the base element further comprises at least one mounting element disposed thereon, the at least one mounting element protrudes from the bottom surface of the base element.

10. The current sensing device of claim 1, wherein the base element is further configured to position the plurality of sensing elements in a predefined orientation with respect to the bus bar element.

11. A current sensing device, comprising:

a plurality of sensing elements, one of the sensing elements comprising a plurality of terminals;

a bus bar element comprising two terminal ends, the plurality of sensing elements collectively being positioned about a portion of the bus bar element; and

a base element having a plurality of apertures disposed therein, the two terminal ends of the bus bar element being received within respective ones of the plurality of apertures, the base element further comprising a post feature that is configured to receive at least one of the plurality of sensing elements.

12. The current sensing device of claim 11, wherein the plurality of terminals are configured to be received within respective ones of the plurality of apertures.

13. The current sensing device of claim 12, wherein the plurality of sensing elements comprises a plurality of turns of a conductive wire, the conductive wire configured to be terminated to the plurality of terminals of the one of the sensing elements.

14. The current sensing device of claim 11, wherein at least one of the sensing elements comprises a wound bobbin, the wound bobbin including a spool portion disposed between two flange portions, the spool portion comprising an inner diameter and an outer diameter.

15. The current sensing device of claim 14, wherein the post feature is sized so as to receive the inner diameter of the spool portion.

16. The current sensing device of claim 15, wherein the base element further comprises a second post feature, the second post feature configured to receive at least one of the sensing elements.

17. The current sensing device of claim 16, wherein the base element further comprises a space between the post feature and the second post feature, the space sized to accommodate at least one of the sensing elements.

18. The current sensing device of claim 17, wherein the post feature, the second post feature and the space are configured to position the plurality of sensing elements in a predefined position around the bus bar element.

19. The current sensing device of claim 18, further comprising a cover element that is configured to be disposed over the plurality of sensing elements, at least portions of the bus bar element, and at least portions of the base element.