Patent Publication Number: US-2021190831-A1

Title: Submersible split core current sensor and housing

Description:
TECHNICAL FIELD 
     The present application generally relates to current sensors, and more particularly, but not exclusively, to a submersible split core current sensor and housing therefor. 
     BACKGROUND 
     Split core current sensors remain an area of interest. Some existing systems have various shortcomings, drawbacks and disadvantages relative to certain applications. For example, some split core current sensors may experience corrosion or other problems in outdoor, underground or submerged applications. Accordingly, there remains a need for further contributions in this area of technology. 
     SUMMARY 
     One embodiment of the present invention is a unique submersible current sensor. Another embodiment is a unique current transformer (CT) sensor. Another embodiment is a submersible housing for a CT sensor. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for current sensors. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
         FIG. 1  schematically illustrates some aspects of a non-limiting example of a submersible split core current transformer (CT) sensor in accordance with an embodiment of the present invention. 
         FIG. 2  schematically illustrates via a cross-sectional view some aspects of a non-limiting example of the submersible split core CT sensor of  FIG. 1 . 
         FIG. 3  schematically illustrates via a cross-sectional view some aspects of a non-limiting example of the submersible split core CT sensor of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS 
     For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates. 
     Referring to  FIG. 1-3 , some aspects of a non-limiting example of a submersible current sensor  10  for sensing a current in a submerged conductor are illustrated in accordance with an embodiment of the present invention. In one form, current sensor  10  is a split core current transformer (CT) sensor. Current sensor  10  is constructed to generate an output representative of the current carried by a submerged conductor  12  (shown in cross-section) that is disposed in or passing through an opening  14  in current sensor  10 , e.g., in the middle of current sensor  10 . Although described herein as being submerged, e.g., in water, salt water or another fluid, and as measuring current in a submerged conductor, it will be understood that current sensor  10  may be employed to measure current in conductors that are not submerged. 
     Current sensor  10  includes a split core transformer  15 . Split core transformer  15  includes a split core transformer part  16  and a split core transformer part  18 . Split core transformer part  16  includes a core member  20  and at least one winding  22  disposed about, e.g., wound about, at least a portion of core member  20 . Split core transformer part  18  includes a core member  24  and at least one winding  26  disposed about, e.g., wound about, at least a portion of core member  24 . In one form, split core members  20  and  24  are half toroids. In other embodiments, split core members  20  and  24  may have other shapes, which may or may not be the same. In one form, core members  20  and  24  have a square cross-section. In other embodiments, core members  20  and  24  may have circular or other cross-sections. Core members  20  and  24  are laminated, and form a high permeability core. In one form, core members  20  and  24  are formed of M4 grade laminated steel. In other embodiments, other materials, e.g., laminated ferrous steel alloys may be employed. In still other embodiments, core members  20  and  24  may be low permeability cores, e.g., formed of plastic or other materials. In some embodiments, core members  20  and  24  may be air cores, e.g., formed of air. 
     Current sensor  10  includes a housing  28 . In one form, housing  28  is in the form of a toroid. In other embodiments, housing  28  may have another geometric shape. In one form, housing  28  has a square cross-section. In other embodiments, housing  28  may have a circular cross-section or may have another cross-sectional shape. Housing  28  is a preformed housing constructed to receive split core transformer part  16  and split core transformer part  18 . In one form, housing  28  is formed of a polymer, e.g., a plastic material. In other embodiments, housing  28  may be formed of other materials in addition to or in place of a polymer, e.g., other non-conductive, non-magnetic materials. Housing  28  includes a housing member  30 , a housing member  32 , a hinge  34  and a latch  36 . 
     Housing member  30  is constructed to receive and house transformer part  16 , e.g., including core member  20  and windings  22 . Housing member  32  is constructed to receive and house transformer part  18 , e.g., including core member  24  and windings  26 . In one form, core member  20  and windings  22  are together encapsulated by, e.g., within, a waterproof resin  38 , e.g., a polyurethane resin, and hermetically sealed within housing member  30 , for example, to protect core member  20  and windings  22  in outdoor, underground or submerged applications. Similarly, core member  24  and windings  26  are together encapsulated by, e.g., within, waterproof resin  38 , and hermetically sealed within housing member  32 , e.g., to protect core member  24  and windings  26  in outdoor, underground or submerged applications. Housing members  30  and  32  protect the encapsulated and sealed core members and windings from damage, e.g., due to foreign objects. In one non-limiting example, core members  20  and  24 , and windings  22  and  26  may be installed in respective housing members  30  and  32 , after which the waterproof resin  38  may be poured into housing members  30  and  32 , encapsulating the core members and windings in the waterproof resin and hermetically sealing and securing them in the respective housing members  30  and  32 . 
     Hinge  34  is disposed on a side  40  of housing  28 , e.g., a side that is radially offset from conductor  12 , and disposed adjacent to ends  42 ,  44  of housing members  30 ,  32 , respectively. In one form, hinge  34  is integral with housing  28 . In other embodiments, hinge  34  may be separate components affixed or adhered to housing  28 . Hinge  34  pivotably couples end  42  of housing member  30  to end  44  of housing member  32 , allowing housing  28  to open up, e.g., to pivot housing members  30  and  32  apart about hinge  34 , in order to place sensor  10  around conductor  12 , e.g., without requiring conductor  12  to be turned off and/or disconnected in order to place sensor  10  around conductor  12 . 
     Latch  36  is disposed on a side  46  of housing  28 . Side  46  is located opposite side  40 , i.e., on the opposite side of housing  28  and conductor  12 . Latch  36  is constructed to releasably secure housing member  30  to housing member  32 . In one form, latch  36  is integral with housing  28 . In other embodiments, latch  36  may be separate components affixed or adhered to housing  28 . In a particular embodiment, latch  36  is constructed to releasably secure end  48  of housing member  30  to end  50  of housing member  32 . In one form, latch  36  is a snap lock mechanism. In other embodiments, latch  36  may take other forms. 
     Latch  36  includes a latch member  52  disposed at end  42  of housing member  30 . In one form, latch member  52  is integral with housing member  30 . In other embodiments, latch member  52  may be a separate component affixed or adhered to housing member  30 . Latch  36  also includes a latch member  54  disposed at end  44  of housing member  32 . In one form, latch member  54  is integral with housing member  32 . In other embodiments, latch member  54  may be a separate component affixed or adhered to housing member  32 . Latch member  52  and latch member  54  are constructed to releasably latch the latch member  52  and the latch member  54  together. For example, in one form, latch member  52  has an opening constructed to receive latch member  54 . Latch member  54  may be, for example, a cantilevered hook  56  that deflects to enter an opening  58  in latch member  52 , and snaps back to engage a latching surface  60  to latch housing  30  and housing  32  together. In the illustrated embodiment, latch  36  may be disengaged by pressing latch member  54  in a direction toward the center of housing  28 , allowing the hook portion of latch member  54  to clear latching surface  60  and disengage from latch member  52 . 
     Sensor  10  includes a cable  62  in electrical communication with windings  22  and windings  26 . Cable  62  electrically couples transformer part  16  and transformer part  18  together. Housing members  30  and  32  include sockets  64  that have openings for receiving the ends of cable  62 , e.g., cylindrical openings in which the ends of cable  62  are disposed. Cable  62  is bonded to and sealed with sockets  64 , e.g., bonded to and sealed with the cylindrical openings, to prevent water or other fluids from penetrating or leaking into sensor  20 . Cable  62  may be bonded and sealed, for example, using waterproof resin  38 . Sensor  10  also includes an output cable  66  coupled to windings  22  and  26 , which provides an output signal for sensor  10 . The end of output cable  66  is disposed within a socket  64  in housing  32 , e.g., in a cylindrical opening in socket  64 , and bonded to and sealed therein, e.g., with waterproof resin  38 . 
     Embodiments of the present invention include a submersible current sensor for sensing a current in a submerged conductor, comprising: a split core current transformer constructed to generate an output representative of the current carried by the conductor, the split core current transformer having a first core member, a first winding disposed about at least a portion of the first core member; a second core member; and a second winding disposed about at least a portion of the second core member; and a preformed housing, the housing including: a first housing member constructed to house the first core member and the first winding; and a second housing member constructed to house the second core member and the second winding. 
     In a refinement, the submersible current sensor further comprises a waterproof resin, wherein the first core member and the first winding are together encapsulated by the waterproof resin; and wherein the second core member and the second winding are together encapsulated by the waterproof resin. 
     In another refinement, the first core member and the first winding are hermetically sealed within the first housing member with the waterproof resin; and wherein the second core member and the second winding are hermetically sealed within the second housing member with the waterproof resin. 
     In yet another refinement, the submersible current sensor further comprises a hinge coupling the first housing member to the second housing member. 
     In still another refinement, the hinge is disposed on a first side of the housing, and couples a first end of the first housing member to a first end of the second housing member, further comprising a latch disposed on a second side of the housing opposite the first side and constructed to releasably secure a second end of the first housing member to a second end of the second housing member. 
     In yet still another refinement, the latch includes a first latch member integral with a second end of the first housing member opposite the first end of the first housing member; and a second latch member integral with a second end of the second housing member opposite the first end of the second housing member, wherein the first latch member and the second latch member are constructed to releasably latch the first latch member and the second latch member together. 
     In a further refinement, the submersible current sensor further comprises a latch constructed to releasably secure the second housing member to the first housing member. 
     In a yet further refinement, the latch is a cantilever snap lock mechanism. 
     In a still further refinement, the housing is a toroid. 
     In a yet still further refinement, the submersible current sensor further comprises an electrical cable in communication with the first winding and/or the second winding, wherein the housing includes a socket, and wherein the cable is disposed within and sealed within the socket. 
     In another refinement, the housing is plastic, and includes an integral hinge and an integral latch. 
     Embodiments of the present invention include a submersible current transformer (CT) sensor, comprising: a polymer housing, including: a first polymer housing member with a first transformer part hermetically sealed therein, wherein the first transformer part includes a first core member and a first winding disposed about at least a portion of the first core member; and a second polymer housing member with a second transformer part hermetically sealed therein, wherein the second transformer part includes a second core member and a second winding disposed about at least a portion the second core member; and a cable coupled to the first transformer part and the second transformer part, wherein a first portion of the cable is sealed within the first polymer housing member and a second portion of the cable is sealed within the second polymer housing. 
     In a refinement, the submersible CT sensor further comprises a waterproof resin, wherein the first transformer part is encapsulated by the waterproof resin and hermetically sealed in the first polymer housing member with the waterproof resin; and wherein the second transformer part is encapsulated by the waterproof resin and hermetically sealed in the second polymer housing member with the waterproof resin. 
     In another refinement, the submersible CT sensor further comprises a hinge coupling the first polymer housing member to the second polymer housing member. 
     In yet another refinement, the hinge is integral with the polymer housing. 
     In still another refinement, the submersible CT sensor further comprises a latch constructed to latch the first polymer housing member to the second polymer housing member. 
     In yet still another refinement, the latch includes a first polymer latch member that is integral with the first polymer housing member, and a second polymer latch member that is integral with the second polymer housing member. 
     Embodiments of the present invention include a submersible housing for a current transformer (CT) sensor, comprising: a first polymer housing member constructed to house: a first split core current transformer part; and a first waterproof resin that encapsulates the first split core transformer part and hermetically seals the first split core current transformer part in the first polymer housing member; a second polymer housing member constructed to house: a second split core current transformer part; and a second waterproof resin that encapsulates the second split core transformer part and hermetically seals the second split core current transformer part in the second polymer housing; a hinge constructed to pivotably couple the first polymer housing member to the second polymer housing member at a first end of the housing; and a latch constructed to releasably attach the first polymer housing member to the second polymer housing member. 
     In a refinement, the hinge is a polymer hinge integral with the submersible housing. 
     In another refinement, the latch includes a first polymer latch member that is integral with the first polymer housing member, and a second polymer latch member that is integral with the second polymer housing member. 
     While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary. 
     Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.