CURRENT SENSING DEVICES AND METHODS

• US 20110025304A1
• Filed: 09/25/2009
• Published: 02/03/2011
• Est. Priority Date: 07/31/2009
• Status: Active Grant

• Current Assignee: Pulse Electronics Incorporated (Yageo Corporation)
• Original Assignee: Pulse Electronics Incorporated (Yageo Corporation)
• Inventors: Lint, James Douglas, Jin, Fuxue, Michel, Francisco, Aldaco, Victor
• Granted Patent: US 9,664,711 B2
• Time in Patent Office: Days
• US Class Current: 324/150
• CPC Class Codes: G01R 15/181 using coils without a magnetic core, e.g. Rogowski coils
• CPC Class Codes: H01F 38/30 Constructions
• CPC Class Codes: H01F 5/02 wound on non-magnetic supports, e.g. formers

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 comprise a number of bobbin elements that are wound and subsequently formed into complex geometric shapes such as torus-like shapes. In an alternative embodiment, bonded windings are utilized which allow the segments to be formed without a bobbin or former. In yet another alternative embodiment, the aforementioned current sensing devices are stacked in groups of two or more. Methods of manufacturing and using the aforementioned current sensing apparatus are also disclosed.

Claims

1. A current sensing inductive device, comprising:

a plurality of segmented winding elements, each element comprising a plurality of winding turns; and

a return conductor that electrically couples a leading one of said plurality of segmented winding elements with a trailing one of said plurality of segmented winding elements.

2. The current sensing inductive device of claim 1, wherein said plurality of segmented winding elements each comprise a bonded wire element formed into a substantially unitary structure.

3. The current sensing inductive device of claim 2, further comprising a plurality of segmented header elements onto which at least a portion of respective ones of said winding elements are disposed.

4. The current sensing inductive device of claim 3, further comprising a return conductor;

wherein at least some of said segmented header elements further comprise a positioning feature that when properly utilized places a return conductor into a predetermined position.

5. The current sensing inductive device of claim 3, wherein at least some of said segmented header elements further comprise a hinged or articulated coupling to others of said segmented header elements.

6. The current sensing inductive device of claim 1, wherein said plurality of segmented winding elements each comprise a bobbin element.

7. The current sensing inductive device of claim 6, wherein each said bobbin element comprises:

a winding channel in which said plurality of windings are disposed; and

a winding aperture, said winding aperture sized to accommodate a respective winding mandrel.

8. The current sensing inductive device of claim 7, wherein said winding aperture comprises a positioning element disposed therein, said positioning element, when properly utilized, places a return conductor into a predetermined position within a central region of said winding elements.

9. The current sensing inductive device of claim 6, wherein each bobbin element comprises a coupling element, which in combination with an adjacent bobbin element, forms a substantially flexible relationship between adjacent ones of bobbin elements.

10. The current sensing inductive device of claim 7, wherein each bobbin element further comprises a pair of flange elements, said flange elements disposed on opposite ends of said winding channel.

11. The current sensing inductive device of claim 10, wherein at least a portion of said flange elements comprise a winding routing feature, said winding routing feature utilized to route individual ones of said plurality of windings from a first winding channel to a second winding channel of an adjacent bobbin element.

12. The current sensing inductive device of claim 10, wherein at least one of said pair of flange elements comprises a positioning feature, said positioning feature adapted to be received within a respective aperture of a header element.

13. The current sensing inductive device of claim 10, wherein each of said flange elements comprises a non-uniform flange width, said non-uniform flange width permitting a full set of bobbin elements to be assembled into a substantially complete torus-like shape.

14. The current sensing inductive device of claim 13, wherein said winding aperture comprises a key feature which facilitates the winding of each of said bobbin elements on said respective winding mandrel.

15. The current sensing inductive device of claim 13, further comprising a routing channel disposed in respective ones of said winding channels of said bobbin elements, said routing channel having a return conductor disposed at least partly therein.

16. A method of manufacturing a current sensing inductive device, comprising:

continuously winding an insulated conductor into a plurality of segmented winding elements;

routing a return conductor between each of said plurality of segmented winding elements; and

electrically coupling said return conductor with said insulated conductor so as to form said current sensing inductive device.

17. The method of claim 16, wherein said act of continuously winding is performed by:

obtaining a plurality of bobbin elements;

placing said plurality of bobbin elements on a winding mandrel; and

continuously winding said insulated conductor onto said plurality of bobbin elements such that adjacent ones of said plurality of bobbin elements are physically coupled via said insulated conductor thereby forming said plurality of segmented winding elements.

18. The method of claim 16, wherein said winding comprises winding said conductor directly onto a mandrel from which the segments can be removed.

19. The method claim 18, further comprising selectively disposing a material on at least one side of said winding elements while on said mandrel.

20. The method claim 19, wherein said at least one side of said winding elements comprises a side that corresponds to an inner circumference of said inductive device when said winding segments are removed from said mandrel and joined.

21. The method claim 18, wherein said selectively disposing a material comprises disposing a ridge or bead of said material only on said portions of said windings associated with said segmented winding elements, and not the interstices between said winding elements.

22. A method of using a current sensing inductive device, comprising:

obtaining a segmented current sensing inductive device;

positioning said segmented current sensing inductive device about a current carrying conductor; and

measuring an output of said segmented current sensing inductive device.

23. The method of claim 22, wherein said segmented inductive device has at least one break or discontinuity in its circumference forming first and second ends, and said positioning comprises:

routing said device around said current carrying conductor by passing said conductor through said break or discontinuity; and

joining the first and second ends so as to enclose or encircle said conductor within a central region of said inductive device.

24. The method of claim 23, wherein said joining comprises placing said first and second ends in a substantially overlapping disposition.

25. The method of claim 23, wherein said joining comprises placing said first and second ends in a substantially non-overlapping, abutted disposition.

26. A current sensing inductive device, comprising:

a plurality of linearly wound inductive elements, each element having a plurality of windings disposed thereon; and

a return conductor that electrically couples a leading one of said plurality of linearly wound inductive elements with a trailing one of said plurality of linearly wound inductive elements.

27. The current sensing inductive device of claim 26, wherein said plurality of linearly wound inductive elements each comprise a bonded wire element formed into a substantially unitary structure.

28. The current sensing inductive device of claim 26, wherein said plurality of linearly wound inductive elements are each held into a substantially unitary structure by the application of an externally applied adhesive.

29. The current sensing inductive device of claim 26, wherein said plurality of linearly wound inductive elements each comprise a wound bobbin element.

30. A current sensing inductive device, comprising:

a first current sensing apparatus, comprising;

a first plurality of segmented winding elements, each element comprising a plurality of windings disposed thereon; and

a first return conductor that electrically couples a leading one of said first plurality of segmented winding elements with a trailing one of said first plurality of segmented winding elements; and

a second current sensing apparatus disposed in an adjacent position with said first current sensing apparatus, said second current sensing apparatus, comprising;

a second plurality of segmented winding elements, each element comprising a plurality of windings disposed thereon; and

a second return conductor that electrically couples a leading one of said second plurality of segmented winding elements with a trailing one of said second plurality of segmented winding elements.

31. The current sensing inductive device of claim 30, wherein said adjacent position comprises a top-to-bottom disposition.

32. The current sensing inductive device of claim 30, wherein said adjacent position comprises a substantially concentrically arranged disposition.

33. The current sensing inductive device of claim 32, wherein said first and second current sensing apparatus have different effective radii.

34. The current sensing inductive device of claim 30, wherein said first and second current sensing apparatus each comprise a plurality of gaps between ones of said segmented winding elements, and the gaps of said first sensing apparatus are disposed proximate the segmented winding elements of the second sensing apparatus, and vice-versa.

35. A method of implementing sensing of a current carrying conductor, the method comprising:

providing a plurality of sensing devices each having a plurality of segmented winding elements and a first associated level of precision;

determining a required level of precision associated with said sensing; and

selecting the appropriate number of said plurality of sensing devices to use for said sensing said current carrying conductor, said selecting being based at least in part on said required level of precision.

36. The method of claim 35, wherein said appropriate number is two or more and said method further comprises disposing said two or more sensing devices in a substantially stacked orientation relative to said conductor.

37. The method of claim 36, wherein said stacked orientation relative to said conductor further comprises the segmented winding elements of a first of said two or more devices being disposed proximate corresponding gaps formed in a second of said two or more sensing devices between the segmented winding elements thereof.