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CN-122003609-A - Current monitoring in wires within an electrical connector

CN122003609ACN 122003609 ACN122003609 ACN 122003609ACN-122003609-A

Abstract

The current sensing apparatus for a wire includes a sleeve of flexible material, wherein the sleeve is tubular and is arranged to fit over a portion of the wire, an inductor comprising a first coil of a first wire formed of a conductive material carried by the sleeve, and a second coil of a second wire disposed on the first wire, the second coil being helical in shape and having a first end that extends to the first end of the second wire and the second coil having a second end that extends to the second end of the second wire, and an integrator circuit coupled to the first end of the second wire and coupled to the second end of the second wire and providing an output voltage that varies according to a magnitude of current in the coil.

Inventors

  • V. Grenez
  • V. R. Dave

Assignees

  • 浩亭国际创新股份公司

Dates

Publication Date
20260508
Application Date
20241002
Priority Date
20231011

Claims (11)

  1. 1. A current sensing apparatus for a wire, comprising: A sleeve of flexible material, wherein the sleeve is tubular and arranged to fit over a portion of a wire; An inductor comprising a first coil of a first wire formed of a conductive material carried by the sleeve, and a second coil of a second wire disposed on the first wire, the second coil being helical in shape and having a first end extending to a first end of the second wire and the second coil having a second end extending to a second end of the second wire, and An integrator circuit coupled to the first end of the second wire and connected to the second end of the second wire and providing an output voltage that varies according to the magnitude of the current in the coil.
  2. 2. The apparatus of claim 1, wherein the second coil is formed by 3D printing of the second wire.
  3. 3. The apparatus of claim 2, wherein the second wire is formed of copper.
  4. 4. The device of claim 1, wherein the first wire has a cross-sectional surface area between 0.01 mm 2 and 0.5 mm 2 and the second wire has a cross-sectional surface area between 0.001 mm 2 and 0.9 mm 2 .
  5. 5. The apparatus of claim 4, wherein the first coil has a pitch between 1 degree and 60 degrees and the second coil has a pitch between 0.4 degrees and 45 degrees.
  6. 6. The apparatus of claim 1, wherein the second coil has a pitch between 0.4 degrees and 45 degrees and the second wire has a cross-sectional surface area between 0.001 mm 2 and 0.9 mm 2 .
  7. 7. The device of claim 1, wherein the first coil has a first end adjacent to a first end of the sleeve and the first coil has a second end adjacent to a second end of the sleeve, a portion of the second wire between the second end of the first coil and the second end of the second wire extending within an interior of the sleeve and being accessible at the first end of the sleeve.
  8. 8. An electrical connector having a housing and a plurality of wires, wherein a portion of each wire is received within the housing, wherein the current sensing device of claim 1 is on the portion of at least one of the wires.
  9. 9. A method of making a current sensing device for a wire includes providing a first wire of conductive material; A second wire of electrically conductive material is printed onto the first wire in a coil, the first wire being formed into a coil before or after the printing step, wherein the second wire has a diameter between 0.001 mm 2 and 0.9 mm 2 and the second coil has a spiral shape having a pitch between 0.4 degrees and 45 degrees.
  10. 10. The method of claim 9, further comprising providing a sleeve around which the first coil is received.
  11. 11. The method of claim 10, comprising the steps of: The method includes providing a first end of the second wire spaced apart from a first end of the sleeve, providing a first end of the first coil adjacent to the first end of the sleeve, providing a second end of the first coil adjacent to the second end of the sleeve, and providing a second end of the second wire with a portion of the second wire extending from the second end of the first coil to the second end of the second wire received within an interior of the sleeve.

Description

Current monitoring in wires within an electrical connector Technical Field The present disclosure relates generally to electrical connectors and to devices for measuring current within wires of electrical connectors. In particular, the present disclosure relates to a current detection device for a wire and to an electrical connector comprising said device. In addition, the present disclosure relates to methods of making the current detection devices. Background An electrical connector is a device that allows electrical current to flow between two or more electrical circuits. Which provides a robust and reliable connection for the transmission of power or signals. Electrical connectors are implemented in various types, shapes, and sizes depending on the particular application and requirements. In an electrical connector, wires play a critical role in establishing an electrical connection between the connector and a device to which the connector is connected. Wires are used to carry electrical signals or power between two mating connectors. In some cases, it may be useful to measure and/or monitor the current flowing within the wires in the electrical connector. For example, measuring the current may help identify any faults or anomalies within the circuit. If the measured current deviates significantly from the expected or normal range, this may indicate a short circuit, overload or other problem that needs to be overcome. Measuring the current may also allow for an assessment of the performance of the circuit. This helps determine whether the current flowing through the wire is within a desired range and whether the circuit is operating as intended. Furthermore, by comparing measured currents at different points in the circuit with expected values, this can help to pinpoint the location of a fault or identify components that are not working properly. In certain applications, such as electrical installation or industrial settings, it may be necessary to measure the current to ensure compliance with safety regulations and standards. Several techniques may be used to monitor the current flowing in the wires of an electrical connector. For example, a current data logger may be connected in series with wires within the electrical connector to continuously measure and log current values over a specific period of time. These recorders store data internally, which can later be downloaded and analyzed to understand current curves and trends. Some electrical connectors may have a built-in current monitoring module that typically includes a current sensing circuit and interface for data acquisition or communication. They allow real-time monitoring and reporting of the current values within the electrical connector. The power monitoring system may also be used to monitor various electrical parameters including current, voltage, power and energy consumption. These systems typically include a current sensor or transducer that can be mounted in the wires of an electrical connector to provide continuous monitoring of the current. However, these known solutions can be very expensive or complex to manufacture and are not always accurate, especially for monitoring wires in an electrical connector that are bent or manipulated during connection. Disclosure of Invention According to a first aspect, a current sensing device for a wire is provided. The current detection device includes a sleeve of flexible material, wherein the sleeve is tubular and is arranged to fit over a portion of the wire, an inductor including a first coil of a first wire formed of a conductive material carried by the sleeve, and a second coil of a second wire disposed on the first wire, the second coil being helical in shape and having a first end that extends to the first end of the second wire and the second coil having a second end that extends to the second end of the second wire, and an integrator circuit coupled to the first end of the second wire and coupled to the second end of the second wire and providing an output voltage that varies according to a magnitude of current in the coil. According to a second aspect, there is provided an electrical connector having a housing and a plurality of wires, wherein a portion of each wire is received within the housing, wherein the current sensing device according to the first aspect is on the portion of at least one of the wires. According to a third aspect, a method of making a current sensing device for a wire is provided. The method includes providing a first wire of conductive material, printing a second wire of conductive material as a coil onto the first wire, forming the first wire into a coil before or after the printing step, wherein the second wire has a diameter between 0.001 mm 2 and 0.9 mm 2, and the second coil has a helical shape having a pitch between 0.4 degrees and 45 degrees. Other aspects and features are defined in the appended claims. Examples of the present disclosure may enable a curr