Low Profile Current Measurement Connector

• US 20150226771A1
• Filed: 02/12/2014
• Published: 08/13/2015
• Est. Priority Date: 02/12/2014
• Status: Active Grant

• Current Assignee: National Instruments Corporation (Emerson Electric Company)
• Original Assignee: National Instruments Corporation (Emerson Electric Company)
• Inventors: Pasternak, David R.
• Granted Patent: US 9,250,272 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: G01R 1/0416 Connectors, terminals G01R1/0425 and G01R1/0433 take precedence; with measurement function for battery poles G01R31/364
• CPC Class Codes: G01R 1/36 Overload-protection arrangements or circuits for electric measuring instruments
• CPC Class Codes: G01R 1/44 Modifications of instruments for temperature compensation
• CPC Class Codes: G01R 15/18 using inductive devices, e.g. transformers
• CPC Class Codes: G01R 19/0092 measuring current only all subgroups of G01R19/00 take precedence
• CPC Class Codes: G01R 3/00 Apparatus or processes specially adapted for the manufacture or maintenance of measuring instruments , e.g. of probe tips
• CPC Class Codes: H01R 13/504 different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
• CPC Class Codes: H01R 13/6633 with inductive component, e.g. transformer
• CPC Class Codes: H01R 2201/20 for testing or measuring purposes
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

A current measurement connector may include a first part and a second part. Each part may include a mount and a joint. The first and second part may be joined via the respective joints through a current transformer interposed between the first and second parts. The respective mounts may be configured to receive a current from a current source and pass the received current through the current transformer via the first and second parts inducing a current in the current transformer. The induced current may be useable to measure the current from the current source. Methods for fabricating the current measurement connector may include die casting the first and second parts and press fitting the first and second parts at the respective joints through the current transformer. Methods for use may include withstanding a fault current pulse and dissipating heat associated with the pulse via the first and second parts.

Claims

1. A current measurement connector, comprising:

a first part, wherein the first part comprises;

a first mount; and

a first joint;

a second part, wherein the second part comprises;

a second mount; and

a second joint; and

a current transformer, interposed between the first part and the second part;

wherein the first part and the second part connect at the first and second joints through the current transformer, thereby electrically coupling the first mount to the second mount, wherein the first mount and the second mount are configured to receive a first current from a current source; and

wherein the current measurement connector is configured to pass the first current from the current source through the first and second joints thereby inducing a second current in the current transformer, wherein the second current is useable to measure the first current.

2. The current measurement connector of claim 1, wherein the first joint is a first cold-forming joint, wherein the second joint is a second cold-forming joint, and wherein the first part and the second part connect at the first and second cold-forming joints via a press fit.

3. The current measurement connector of claim 1, wherein the first part further comprises:

one or more soldering pins, wherein the one or more soldering pins are configured to mount via a wave soldering process to a printed circuit board via through holes disposed in the printed circuit board.

4. The current measurement connector of claim 3, wherein the first part is not electrically coupled to the printed circuit board.

5. The current measurement connector of claim 1, wherein the first part and the second part are die cast from one or more of zinc, aluminum, or copper.

6. The current measurement connector of claim 1, further comprising:

an overmold, wherein the overmold;

encapsulates the first and second parts connected through the current transformer;

electrically isolates the current measurement connector;

thermally insulates the current measurement connector; and

mechanically isolates the current measurement connector from mechanical vibration.

7. The current measurement connector of claim 1, wherein the current measurement connector is able to withstand fault current pulses of at least approximately one thousand two hundred and fifty amperes for at least approximately one cycle, thereby protecting the current transformer from damage.

8. The current measurement connector of claim 1, wherein the current measurement connector is able to dissipate heat associated with fault current pulses of at least approximately one thousand two hundred and fifty amperes for at least approximately one cycle, thereby protecting the current transformer from damage.

9. The current measurement connector of claim 1, further comprising:

a spacer, interposed between the first mount and the second mount, wherein the spacer is configured to;

isolate the first mount and second mount from mechanical vibration; and

prevent an alternative electrical coupling between the first mount and second mount.

10. The current measurement connector of claim 1, wherein, when connected, the first and second joints implement at least a portion of a primary coil.

11. The current measurement connector of claim 1, wherein the first mount is further configured to electrically couple to a first wire lug via a first threaded fastener, wherein the second mount is further configured to electrically couple to a second wire lug via a second threaded fastener, and wherein the first and second wire lug are electrically coupled to the current source.

12. A method for manufacturing a current measurement connector, the method comprising:

casting a first part of the current measurement connector, wherein the first part comprises;

a first mount; and

a first joint;

casting a second part of the current measurement connector, wherein the second part comprises;

a second mount; and

a second joint; and

joining the first part and the second part via the first and second joints through a current transformer interposed between the first part and the second part, thereby electrically coupling the first mount to the second mount, wherein the first mount and the second mount are configured to receive a first current from a current source;

wherein the current measurement connector is configured to pass the first current through the first and second joints thereby inducing a second current in the current transformer, wherein the second current is useable to measure the first current.

13. The method of claim 12, wherein the first part further comprises:

one or more soldering pins, wherein the one or more soldering pins are configured to mount via a wave soldering process to a printed circuit board via through holes disposed in the printed circuit board.

14. The method of claim 12, wherein the first joint is a first cold-forming joint, wherein the second joint is a second cold-forming joint, and wherein said joining further comprises press fitting the first part and the second part via the first and second cold-forming joints.

15. The method of claim 12, further comprising:

applying, after said joining, an overmold, wherein the overmold;

encapsulates the first and second parts connected through the current transformer;

electrically isolates the current measurement connector;

thermally insulates the current measurement connector; and

mechanically isolates the current measurement connector from mechanical vibration.

16. The method of claim 12, wherein said joining further comprises:

interposing a spacer between the first mount and the second mount, wherein the spacer is configured to;

isolate the first mount and second mount from mechanical vibration; and

prevent an alternative electrical coupling between the first mount and second mount.

17. The method of claim 12, further comprising:

plating the first and second parts with tin, wherein the tin prevents galvanic corrosion of the first and second mounts.

18. The method of claim 12, wherein the first part and the second part are die cast from one or more of zinc, aluminum, or copper.

19. A method for measuring current, the method comprising:

connecting a current source to a current measurement connector via a first and second mount of the current measurement connector, wherein the current measurement connector comprises a first part and a second part, wherein the first part and the second part connect at respective cold-forming joints through a current transformer interposed between the first and second parts; and

passing, via the current measurement connector, a first current from the current source through the respective cold-forming joints thereby inducing a second current in the current transformer, wherein the second current is useable to measure the first current.

20. The method of claim 19, further comprising:

applying a fault current pulse, wherein the fault current pulse is at least approximately one thousand two hundred and fifty amperes for at least approximately one cycle; and

dissipating, via the first and second parts, heat associated with said applying thereby withstanding said applying and protecting the current transformer.