阅读说明：本技术 用于高电压可分离连接器的具有分立电容器的传感器 (Sensor with discrete capacitor for high voltage separable connector ) 是由 贾伊隆·D·劳埃德 克里斯多佛·R·威尔逊 卡洛·J·温策尔 于 2018-05-08 设计创作，主要内容包括：本发明公开了一种用于可分离连接器的传感器,该传感器包括插头主体、一个或多个高电压电容器、一个或多个低电压电容器以及低电压连接件。该插头主体包括绝缘树脂。该插头主体能够插入到可分离连接器内以包封设置在可分离连接器中的高电压导体。该一个或多个高电压电容器被绝缘树脂包封,并且能够在插头主体插入时在第一端部部分处电联接到可分离连接器。该一个或多个低电压电容器以串联方式电联接到一个或多个高电压电容器以形成电容分压器。该低电压连接件提供对应于可分离连接器中存在的高电压信号的低电压信号。还可包括信号调节电子器件或存储器。(A sensor for a separable connector includes a plug body, one or more high voltage capacitors, one or more low voltage capacitors, and a low voltage connection. The plug main body includes an insulating resin. The plug body is insertable into the separable connector to enclose a high voltage conductor disposed in the separable connector. The one or more high-voltage capacitors are encapsulated by an insulating resin and can be electrically coupled to the separable connector at the first end portion when the plug main body is inserted. The one or more low voltage capacitors are electrically coupled in series to one or more high voltage capacitors to form a capacitive voltage divider. The low voltage connection provides a low voltage signal corresponding to a high voltage signal present in the separable connector. Signal conditioning electronics or memory may also be included.)

1. A sensor for a separable connector, comprising:

a plug main body including an insulating resin, the plug main body configured to be inserted into the separable connector to enclose a high-voltage conductor provided in the separable connector;

one or more high voltage capacitors encapsulated by the insulating resin and configured to be electrically coupled to the separable connector at a first end portion when the plug main body is inserted;

one or more low voltage capacitors electrically coupled in series to the one or more high voltage capacitors to form a capacitive voltage divider; and

a low voltage connection configured to provide a low voltage signal corresponding to a high voltage signal present in the separable connector.

2. The sensor of claim 1, comprising a high voltage connection configured to couple to the high voltage conductor disposed in the separable connector and receive the high voltage signal from the separable connector.

3. The sensor of any one of the preceding claims, wherein the insulating resin is configured to transfer torque from a low voltage first end portion of the plug body to a high voltage second end portion of the plug body to secure the sensor to the separable connector.

4. The sensor of any preceding claim, wherein the plug body further comprises a torque structure comprising at least one of:

a projection structure, and

one or more grooves in the insulating resin.

5. The sensor of claim 4, wherein the protrusion structure is formed from the insulating resin or from a separate insulating material.

6. The sensor of any one of the preceding claims, wherein a screw mechanically and electrically couples at least one of the high voltage capacitors with at least one of:

the one or more low voltage capacitors, and

another one of the one or more high voltage capacitors.

7. The sensor of any one of the preceding claims, further comprising a ground connection electrically coupled to the one or more low voltage capacitors.

8. The sensor of any preceding claim, wherein the low voltage connection comprises a cable extending from an end portion of the sensor assembly.

9. The sensor of any preceding claim, further comprising a substrate supporting the one or more low voltage capacitors.

10. The sensor of any one of the preceding claims, wherein at least one of the one or more low voltage capacitors is encapsulated by the insulating resin.

11. The sensor of any one of the preceding claims, further comprising signal conditioning electronics configured to electrically couple to the one or more low voltage capacitors.

12. The sensor of claim 11, wherein the signal conditioning electronics are detachably or integrally connected to the one or more low voltage capacitors.

13. The sensor of claim 12, wherein the plug body includes a low voltage end portion that is separable from the plug body, the plug body including a first portion including signal conditioning electronics and a second portion that is detachably connected to the first portion and includes at least the low voltage capacitor.

14. The sensor of any one of claims 1 to 12, wherein the plug body comprises a low voltage end portion separable from the plug body, the plug body comprising a first portion comprising the one or more low voltage capacitors and a second portion separably connected to the first portion and comprising the one or more high voltage capacitors.

15. The sensor of any preceding claim, further comprising an insulating cap to cover an end of the plug body.

16. The sensor of any one of the preceding claims, further comprising another low voltage connection configured to receive a signal corresponding to a current signal present in the separable connector.

17. The sensor of any preceding claim, further comprising a memory configured to store at least one of a unique product identifier, manufacturing data, calibration ratios, signal conditioned gain values, and installation data.

18. The sensor of any one of the preceding claims, wherein the low voltage signal indicates that the high voltage signal has an error of less than or equal to about 1% over an operating temperature range of about-5 ℃ to about 40 ℃.

19. The sensor of any one of the preceding claims, wherein the low voltage signal corresponds to the high voltage signal at a ratio of between about 1:100 and about 1:100,000.

20. The sensor of any preceding claim, wherein the one or more high voltage capacitors each have a voltage rating of at least about 3 kV.

21. A network comprising a sensor according to any preceding claim.

22. A shielded terminal comprising a sensor according to any preceding claim.

Background

As power distribution becomes more complex due to the advent of renewable energy sources, distributed power generation, and the adoption of electric vehicles, intelligent power distribution and associated electrical sensing becomes more useful and even necessary. Available sensing may include voltage, current, and time relationships between voltage and current at various locations within the power distribution network.

Many existing relatively high voltage transformers and switchgear have dedicated space for cable accessories, especially in higher voltage applications (e.g., 5kV to 69kV or higher). Many of these transformers and switchgear are of the type known in the power industry as dead front ends. Dead front means that there are no exposed relatively high voltage surfaces in the connection between the power cable and the transformer or switchgear. Such cable fitting connections are sometimes referred to as elbows, T-shaped bodies, or separable connectors.

Many cable assemblies are equipped with test points to provide a nominal fraction of the line voltage on the shielded and insulated conductors of the cable assembly. The historical use of these test points is to indicate the line voltage present at the transformer or switchgear. Typically, these test points do not provide the voltage ratio accuracy required for modern grid automation power quality and control applications.

Disclosure of Invention

Generally, the present disclosure relates to sensors for high voltage, which may also be used as an insulating plug. The present disclosure includes a sensor having a discrete capacitor that may be at least partially encapsulated in an insulating resin forming at least a portion of a plug body. The sensor may provide a low voltage signal corresponding to a high voltage signal present in the separable connector. In some examples, the present disclosure relates to a sensor for a high voltage separable connector.

Various aspects of the present disclosure relate to sensors for separable connectors. The sensor includes a plug body, one or more high voltage capacitors, one or more low voltage capacitors, and a low voltage connection. The plug main body has an insulating resin and is configured to be inserted into the separable connector to enclose a high-voltage conductor provided in the separable connector. The one or more high-voltage capacitors are encapsulated by an insulating resin and are configured to be electrically coupled to the separable connector at the first end portion when the plug main body is inserted. The one or more low voltage capacitors are electrically coupled in series to one or more high voltage capacitors to form a capacitive voltage divider. The low voltage connection is configured to provide a low voltage signal corresponding to a high voltage signal present in the separable connector.

It is to be understood that both the foregoing general description and the following detailed description present embodiments of the presently disclosed subject matter, and are intended to provide an overview or framework for understanding the nature and character of the presently disclosed subject matter as it is claimed.

Drawings

Fig. 1 is an exploded view of a cable accessory system including a separable connector, a sensor, and an insulating cap.

Fig. 2A, 2B, and 2C are schematic diagrams of various sensor configurations used with the system of fig. 1.

Fig. 3 is a perspective view of an exemplary sensor.

Fig. 4 is a perspective view of the exemplary sensor of fig. 4 without the plug body.

FIG. 5 is a cross-sectional view of the exemplary sensor of FIG. 4 on a plane extending through the exemplary sensor along the longitudinal axis.

Fig. 6 is a perspective view of a substrate of the exemplary sensor of fig. 4.

FIG. 7 is a perspective view of another exemplary sensor.

Fig. 8 is a cross-sectional view of the exemplary sensor of fig. 7.

Fig. 9 is a perspective view of the partially assembled exemplary sensor of fig. 7 without the plug body.

Fig. 10 is a perspective view of the partially assembled exemplary sensor of fig. 7 with a partially assembled plug body.

FIG. 11 is a cross-sectional view of another exemplary sensor.

FIG. 12 is a perspective, cross-sectional end view of the exemplary sensor of FIG. 11 taken along line 12-12.

The present disclosure may be understood more fully by consideration of the following detailed description of various embodiments of the disclosure and the accompanying drawings.

Detailed Description

The present disclosure provides sensors for high voltage separable connectors that each have a discrete capacitor and provide a low voltage signal corresponding to a high voltage signal present in the separable connector at least partially encapsulated in an insulating resin forming at least a portion of the plug body. The sensor may be used as an insulating plug for the separable connector. One or more high voltage capacitors may be encapsulated by an insulating resin. One or more low voltage capacitors may be encapsulated by an insulating resin. The low voltage connection may provide a low voltage signal, which may correspond to a voltage on the one or more low voltage capacitors. The plug body may be unitary or separable, which may allow one or more components to be separated from other components of the sensor. The sensor may also include a substrate for supporting one or more components. Signal conditioning electronics may be disposed proximate the low voltage signal to provide a conditioned low voltage signal.

The sensors described herein provide convenient and easy to use voltage sensing and insulation of high voltage separable connectors. The sensor may be used as an insulating plug that does not have an exposed high voltage surface when inserted into the separable connector. Voltage sensing capability over a wider operating temperature range and a wider range of harmonic frequencies may be more accurate than using a resistive divider that may be susceptible to parasitic capacitance at higher harmonics or frequencies. The capacitive voltage divider may facilitate measurements beyond the fundamental frequency or fundamental frequency, and may facilitate the use of standard high voltage DC debug tests without additional leakage current through the voltage divider. The sensors may be used in smart grid applications where such accuracy is required. The separable plug body utilizing the sensors may allow for maintenance or replacement of some components without service outages or other interruptions. Signal conditioning in the immediate case may improve the signal-to-noise ratio of the conditioned voltage signal before the signal picks up additional noise, for example via transmission of an external cable.

As used herein, the term "high voltage" refers to a voltage equal to or greater than a high voltage threshold. The high voltage threshold may be based on standards, jurisdictional requirements, or end-user requirements applied to the particular system being described. For example, high voltage may refer to operation at about the rated voltage defined in a standard, such as the Institute of Electrical and Electronics Engineers (IEEE) standard 386(2016) for separable insulated connector systems for power distribution systems rated at 2.5kV to 35kV (classified as phase-to-phase root mean square or rms), which is incorporated by reference herein for any and all purposes. Depending on the application, the high voltage threshold may be equal to or greater than about 2.5kV, about 3kV, about 5kV, about 15kV, about 25kV, about 28kV, about 35kV, about 69kV, or higher voltages (classified as phase-rms).

As used herein, the term "low voltage" refers to a voltage that is less than the high voltage. A low voltage may be defined as being at or below a low voltage threshold. The low voltage threshold and the high voltage threshold may be the same threshold or different thresholds. The low voltage may be a fraction or ratio less than 1 of the high voltage. The low voltage may be defined by a threshold fraction or ratio (e.g., less than or equal to about 1: 100). Unless otherwise indicated in the disclosure herein, phase-ground rms is used to describe the low voltage.

As used herein, the term "separable connector" refers to a connection or interface for a high voltage system that can be easily established or disconnected by engaging or disengaging the connection at a working interface. The separable connector may be fully insulated and shielded, and may be used to terminate and insulate a power cable, insulate another electronic component, or connect an insulated power cable to electrical equipment, other power cables, or both. The separable connector may be connected to a transformer or a switching device. Some separable connectors can be used for dead-front transformers and switchgear that in the power industry means that there is no exposed high voltage surface in the connector between the power cable and the transformer or switchgear. Non-limiting examples of separable connectors include elbow-shaped separable insulated connectors and T-shaped separable insulated connectors (e.g., T-shaped bodies).

As used herein, the term "rated voltage" refers to the maximum voltage designed to operate the connector. The nominal voltage may be measured as the highest phase-ground voltage rms of a single-phase system, or may be measured as the highest phase-ground and phase-phase voltages rms of a three-phase system. However, any suitable type of rated voltage may be used to describe the maximum operating voltage. Unless otherwise indicated in the disclosure herein, nominal voltage refers to the phase-ground rms.

As used herein, the term "connector" refers to an interface, connector, or other structure for electrically or mechanically coupling components together. For example, the connection may include a plug or socket, a wire, a cable, a conductor on a substrate, a solder member, a conductive via, or other similar electrical or mechanical coupling.

The terms "coupled" or "connected" mean that two elements are attached to each other either directly (in direct contact with each other) or indirectly (with one or more elements located between and attaching the two elements).

Fig. 1 shows a system 100 including a sensor 102, a separable connector 104, and an insulating cap 106. The system 100 and its components may be sized and shaped to meet or otherwise be compatible with applicable standards, jurisdictional requirements, or end-user requirements of a separable insulated connector system. For example, the system 100 may be designed to meet IEEE standard 386(2016) for an insulated plug for a separable connector. In particular, the sensor 102 may be designed to function as a 600A insulating plug. As another example, the system 100 may be designed to meet similar International Electrotechnical Commission (IEC) standards prevalent in europe, which may employ different sizes and shapes for compatibility.

As shown, the sensor 102 may be in the shape of an insulated plug. The sensor 102 may be inserted into the receptacle 108 of the separable connector 104 and encapsulate or otherwise cover a high voltage conductor or high voltage conductive surface disposed within the cavity. The separable connector 104 may include one, two, or more receptacles 108 (e.g., in a T-shaped body).

The sensor 102 may be plugged in the same manner as a conventional insulated plug. In some embodiments, the sensor 102 may include a shoulder and a taper, and the receptacle 108 has a complementary structure. The high voltage connector of the separable connector 104 can be a threaded rod and the sensor 102 can include a high voltage connection with complementary threads. The sensor 102 may be threaded onto a threaded high voltage conductor to secure the sensor 102 to the separable connector 104.

After being inserted and optionally secured, the sensor 102 may cover all or at least some of the high voltage surfaces in the receptacle 108 that would otherwise be exposed. An extension 110 of the sensor 102 may extend out of the receptacle 108 of the separable connector 104. The extension 110 may include a torque structure, such as a hex-shaped protrusion (described in more detail herein). An insulating cap 106 may be disposed over the sensor 102 to cover the extension 110. The insulative cap 106 may be frictionally secured to the separable connector 104. The insulative cap 106 can slide over at least a portion of the separable connector 104 and can be pulled away to expose the sensor 102. In some embodiments, the extension portion 110 of the sensor 102 may have an outer surface formed of an insulating material, and the insulating cap 106 may not be required.

The sensor 102 may be a voltage sensor. The sensor 102 may provide a low voltage signal corresponding to a high voltage signal present in the separable connector 104. The low voltage signal may be described as a voltage channel. The sensor 102 may include one or more capacitors. In some embodiments, the capacitor includes at least a low voltage capacitor and at least a high voltage capacitor. The capacitor may be arranged as a voltage divider to provide a low voltage signal. For example, the low voltage signal may correspond to a divided voltage signal.

The sensor 102 may provide accuracy of a low voltage signal representative of a high voltage signal, allowing use in various smart grid applications to diagnose degradation or other problems in a connected transformer, switchgear, or larger connected grid, such as trips, sags, swells, and other events. Higher precision sensors may facilitate the detection of smaller events or may facilitate more accurate diagnosis of events. For example, for VOLT VAR control, some accuracy (e.g., 0.7%) may be required to detect changes in the system, such as when a change occurs in the on-load tap changer in the transformer. The precision may be defined as being less than or equal to the error value. Non-limiting examples of error values include about 1%, about 0.7%, about 0.5%, about 0.3%, about 0.2%, about 0.1%, or less.

The temperature range over which the sensor 102 is accurate can be described as the operating temperature range. Within the operating temperature range, the accuracy may be less than or equal to the error value for all temperatures within the range. The operating temperature range may be designed to meet standards, jurisdictional requirements, or end-user requirements. Non-limiting examples of operating temperature ranges include lower limits of equal to or greater than about-40 ℃, about-30 ℃, about-20 ℃, about-5 ℃ or higher. Non-limiting examples of operating temperature ranges include an upper limit equal to or less than about 105 ℃, about 85 ℃, about 65 ℃, about 40 ℃ or less. Non-limiting examples of operating temperature ranges include between about-5 ℃ to about 40 ℃, about-20 ℃ to about 65 ℃, about-30 ℃ to about 85 ℃, about-40 ℃ to about 65 ℃, and about-40 ℃ to about 105 ℃.

The sensor 102 may have a voltage rating or be rated to operate in a high voltage system, such as the system 100. The sensor 102 may function as a voltage sensor, an insulating plug, or both. The nominal voltage may be designed to meet standards, jurisdictional requirements, or end-user requirements. Non-limiting examples of the rated voltage of the sensor 102 in a three-phase system include about 2.5kV, about 3kV, about 5kV, about 15kV, about 25kV, about 28kV, about 35kV, or about 69kV (classified as phase-to-phase rms). In some embodiments, the nominal voltage is at least 5 kV.

The frequency range over which the sensor 102 is accurate can be described as the operating frequency range. The frequency response over the operating frequency range may be flat or substantially flat, which may correspond to minimal variation. Non-limiting examples of flatness may include plus or minus (+/-) about 3dB, about 1dB, about 0.5dB, about 0.1 dB. The frequency response may be designed to meet standards, jurisdictional requirements, or end-user requirements. The operating frequency range may extend to about the 50 th harmonic, or even up to the 63 rd harmonic, of the fundamental frequency of the high voltage signal present in the separable connector 104. Non-limiting examples of operating frequency ranges may include one or more of a fundamental frequency of about 60Hz (or about 50Hz), a 50 th harmonic of about 3kHz (or about 2.5kHz), a 63 th harmonic of about 3.8kHz (or about 3.2kHz), and higher frequencies. The frequency response may also remain stable over all or substantially all of the operating temperature range. Some Remote Terminal Units (RTUs) or Intelligent Electronic Devices (IEDs) may utilize one or more of these higher order harmonics.

Fig. 2A, 2B, and 2C illustrate various configurations 200, 220, 240 for a voltage sensor of the present disclosure, such as voltage sensor 102. Each configuration 200, 220, 240 includes a high voltage connection 202, one or more high voltage capacitors 204, one or more low voltage capacitors 206, and optional electronics 208. One or more of these components may be enclosed by the plug body 210, 222, 242 or portions thereof. The portion enclosed by the plug body 210, 222, 242 may be considered part of the plug body. The plug bodies 210, 222, 242 may be formed, or at least partially formed, of an insulating material, such as an insulating resin or other insulating polymer. In some implementations, the capacitors 204, 206 are formed of a different capacitive material than the plug bodies 210, 222, 242.

The high voltage connection 202 may need to withstand the full voltage of a separable connector, such as the separable connector 104. The one or more high-voltage capacitors 204 and the plug bodies 210, 222, 242 may need to at least partially withstand the voltage of the separable connectors.

Any suitable resin may be used that has a high dielectric strength and mechanical properties suitable for transmitting torque between components. For example, a cycloaliphatic epoxy resin may be used as the insulating resin. In some embodiments, a portion of the plug body may be formed from a different polymer, such as polycarbonate, acetal thermoplastic, or phenolic composite.

High voltage connection 202 may receive a high voltage signal V from a separable connector, such as separable connector 104_H. In particular, the high voltage connection 202 may be coupled to a high voltage conductor disposed in the separable connector. In particular, the high voltage connection 202 may enclose the high voltage conductor of the separable connector. The high voltage connection 202 may be formed of any suitable conductive material. The high voltage connection 202 may be formed of the same material as the high voltage conductor provided in the separable connector, which may facilitate thermo-mechanical compatibility. In some embodiments, the high voltage connection 202 comprises any suitable electrically conductive material. Non-limiting examples of materials for the high voltage connection 202 include aluminum and copper. Aluminum may be used in a 600 amp system. Copper may be used in a 900 amp system.

One or more high voltage capacitors 204 are operably coupled to the high voltage connection 202 and one or more low voltage capacitors 206. In some embodiments, at least some of the high voltage capacitors 204 are electrically coupled in series, in parallel, or both. The one or more low voltage capacitors 206 may be the same or different (e.g., in terms of capacitance, voltage rating, size, mounting pattern, or shape). In some embodiments, more high voltage capacitors 204 may be coupled in series for higher sensor voltage ratings. When at least a portion of the plug body 210, 222, 242 is inserted into the separable connector, the one or more high-voltage capacitors 204 may be electrically coupled to the separable connector by the high-voltage connection 202. Each of the high-voltage capacitors 204 may have a higher voltage rating than each of the low-voltage capacitors 206. Non-limiting examples of the voltage rating of the high voltage capacitor 204 include ratings of at least about 2.5kV, about 3kV, about 5kV, about 10kV, about 15kV, about 20kV, about 25kV, or about 30 kV.

Each of the high-voltage capacitors 204 has a capacitance. In some embodiments, the capacitance may be selected in the range of about 10pF to about 100 pF. Non-limiting examples of capacitances include about 10pF, about 30pF, about 50pF, about 70pF, and about 90 pF.

Each of the high voltage capacitors 204 has an impedance. The magnitude of the impedance at the fundamental frequency (e.g., 50/60Hz) may be equal to a large impedance value, such as about 100M Ω.

Each of the high voltage capacitors 204 may be a ceramic capacitor. Ceramic capacitors can provide accuracy and stability over a range of operating temperatures. Non-limiting examples of types of ceramic capacitors include class 1 dielectrics, such as C0H, C0G, and NP 0.

Each of the high-voltage capacitors 204 may be encapsulated by the insulating resin of the plug main body 210, 222, 242.

One or more low voltage capacitors 206 are operably coupled to the one or more high voltage capacitors 204 and optional electronics 208. The one or more low voltage capacitors 206 may be electrically coupled in series to the one or more high voltage capacitors 204. In some embodiments, at least some of the low voltage capacitors 206 are electrically coupled in series, in parallel, or both. The one or more low voltage capacitors 206 may be the same or different (e.g., in terms of capacitance, voltage rating, size, mounting pattern, or shape). The one or more low voltage capacitors 206 may be electrically coupled in series to the one or more high voltage capacitors 204. The low voltage signal V may be provided between one or more low voltage capacitors 206 and one or more high voltage capacitors 204_L. Ground V provided at opposite ends of the one or more low-voltage capacitors 206_GMay be coupled to system ground.

Each of the low-voltage capacitors 206 has a capacitance. In some embodiments, the capacitance can be selected in the range of about 0.1 μ F to about 1 μ F. Non-limiting examples of capacitances include about 0.1 μ F, about 0.3 μ F, about 0.5 μ F, about 0.7 μ F, and about 0.9 μ F. The capacitance values may be selected to provide a capacitance ratio of the high voltage capacitor 204 to the low voltage capacitor 206 of about 100:1, about 1,000:1, about 10,000:1, or about 100,000: 1.

Each of the low voltage capacitors 206 has an impedance. The magnitude of the impedance at the fundamental frequency (e.g., 50/60Hz) may be equal to a low impedance, such as about 10k Ω.

Each of the low voltage capacitors 206 may be a ceramic capacitor. Ceramic capacitors can provide accuracy and stability over a range of operating temperatures. Each of the low voltage capacitors 206 may be a surface mount capacitor. The size of each of the low-voltage capacitors 206 may be smaller than the size of each of the high-voltage capacitors 204.

Each of the low-voltage capacitors 206 may be encapsulated by the insulating resin of the plug main body 210 or the portions 224, 246 of the plug main bodies 222, 242.

The capacitors 204, 206 may be tuned to a high voltage signal V_HDividing to provide a low voltage signal V_L. Low voltage signal V_LCan be a high voltage signal V_HThe fraction of (c). Low voltage/high voltage ratio (V)_L/V_H) May be about 1:100, about 1:1,000, about 1:10,000, or about 1:100,000. Low voltage signal V_LMay have a maximum voltage of less than or equal to about 0.5V, about 1V, about 10V, about 42V, about 100V, or about 300V.

The electronics 208 are operably coupled to one or more low voltage capacitors 206. The electronic device 208 may receive the low voltage signal V_L. The electronics 208 may provide the regulated voltage signal V_CTo a low voltage connection. The electronics 208 may be coupled to ground V_G。

The electronics 208 may be coupled in close proximity to the high voltage signal V_HAnd a low voltage signal V_L. In some embodiments, the electronics 208 and capacitors 204, 206 are integrated into the same plug body 210. In some embodiments, the electronic device 208 is detachably connected to one or more low voltage capacitors 206. In some embodiments, the electronics 208 are integrated into the same portion (e.g., portion 246 of the plug body 242) as the one or more low-voltage capacitors 206, which one or more low-voltage capacitors 206 are detachably connected to the one or more high-voltage capacitors 204.

Signal conditioning may be included in electronics 208. Non-limiting examples of signal conditioning include voltage amplification, voltage filtering, voltage line drive or buffering, current amplification, current integration, current filtering, and current line drive or buffering. The conditioned signal may be capable of being transmitted to an RTU or other device through an external cable.

The memory may be included in the electronics 208. The memory may be provided on a single component or may be provided on two or more separate components. In some embodiments, a portion of the memory may be disposed on a different portion of the plug body 210, 222, 242. In some embodiments, the memory may be located remotely from the signal conditioning electronics (e.g., external to the plug body).

A memory is operatively coupled to the low voltage connection and stores data such as a unique product identifier, manufacturing data, a calibration ratio of the voltage divider, and a gain value of the signal conditioning electronics.

The unique product identifier may correspond to a particular sensor, such as a serial number.

The calibration ratio may include a voltage ratio and a current ratio for a particular sensor. The sensors may be pre-calibrated before reaching the end user or calibrated in the field. In some embodiments, the calibration ratio may be updated as components age or certain separable components are replaced or otherwise replaced.

A device using a sensor may be able to acquire a unique product identifier and a calibration ratio. The stored calibration may be automatically read by the connected device such that the stored ratio value is automatically applied by the connected device. Compared to manual entry of these values, automated applications may save time, may avoid incorrect or erroneous data entry, and may reduce the likelihood of other errors.

Certain locations within the memory may be left empty for storing installation data for the end user at installation time. For example, the location, connected equipment, installer name, and voltage phase (typically A, B or C) may be programmed at installation. This may leave a "built" record within the sensor that may be automatically read at a later date.

The memory may be present on a bus with several sensors or electronics that can be interrogated to determine characteristics and relationships between connected devices, for example via low voltage connectors.

The controller may be included in the electronics 208. The controller may manage access to or include memory. In some embodiments, the controller facilitates communication between the sensor and the connected device.

The controller may include a processor, such as a Central Processing Unit (CPU), computer, logic array, or other device capable of directing data into or out of the sensor. In some embodiments, the controller includes one or more computing devices having storage, processing, and communication hardware. The functions of the controller may be performed by hardware and/or as computer instructions on a non-transitory computer readable storage medium.

The plug bodies 210, 222, 242 may be arranged as a unitary body or as a separable body. In some embodiments, such as configuration 200, plug body 210 is a one-piece body. The plug body 210 encloses the high voltage connection 202, the one or more high voltage capacitors 204, the one or more low voltage capacitors 206, and the electronics 208.

In some embodiments, such as configuration 220, plug body 222 includes a first portion 224 and a second portion 226 connectable and separable from the first portion. The first portion 224 encloses the high voltage connection 202, the one or more high voltage capacitors 204, and the one or more low voltage capacitors 206. Second portion 226 encapsulates electronic device 208. The electronics 208 may be replaced or otherwise replaced when the sensor is inserted into the separable connector without a service outage.

In some embodiments, such as configuration 240, the plug body 242 includes a first portion 244 and a second portion 246 connectable and separable from the first portion. The first portion 244 encloses the high voltage connection 202 and the one or more high voltage capacitors 204. The second portion 246 encapsulates the one or more low voltage capacitors 206 and the electronic device 208. When the sensor is inserted into the separable connector without a service outage, the electronics 208, the one or more low voltage capacitors 206, or both may be replaced or otherwise replaced.

The separable plug bodies 222, 242 may define the first portions 224, 244 as high voltage end portions and the second portions 226, 246 as low voltage end portions. The low voltage end portion may be considered a separable portion. The high voltage end portion may be considered as a separable portion. The low voltage end portion or the high voltage end portion may be considered a sensor assembly end portion.

The different portions 224, 226, 244, 246 of the separable plug bodies 222, 242 may be formed of the same or different materials. One or both portions 224, 226, 244, 246 of the separable plug bodies 222, 242 may be formed from an insulative material, such as an insulative resin, polycarbonate, acetal thermoplastic, or phenolic composite material.

Components such as the electronics 208 and the one or more low voltage capacitors 206 may need to be maintained, replaced, or otherwise replaced more frequently than other components such as the one or more high voltage capacitors 204, the high voltage connection 202, and the plug bodies 210, 222, 242.

Fig. 3, 4, 5, and 6 illustrate different views of an exemplary sensor 300. Fig. 3 shows a perspective view of an exemplary sensor 300. Fig. 4 shows a perspective view of an exemplary sensor 300 without a plug body 310. Fig. 5 shows a cross-sectional view of an exemplary sensor 300. Fig. 6 shows a perspective view of a substrate 338 supporting some of the other components of the exemplary sensor 300.

Many of the parts and components shown in fig. 3-6 are the same or similar to those shown and described with reference to other figures described herein. For similarly numbered elements shown with reference to fig. 3-6 but not specifically discussed in detail, reference is made to the discussion regarding other figures described herein.

As shown, the exemplary sensor 300 includes: a plug main body 310; a low voltage connection 330 including providing a low voltage signal V to an external device_LThe cable of (1); a ground connector 332 connected to the ground V_G(ii) a And a torque structure 334 comprising a hexagonal protrusion. The plug body 310 is a one-piece plug body. The torque feature 334 is formed separately from the plug body 310 and may be formed of a different material than the plug body. In an alternative embodiment, the torque structure 334 may comprise a conductive or semiconductive material. For example, the torque structure 334 may comprise aluminum. The ground connection 332 is electrically coupled to one or more low voltage capacitors 306.

The plug body 310 may extend from a high voltage end portion 311 to a low voltage end portion 313. The cable of the low voltage connection 330 may extend partially from the low voltage end 313. The cable may be a shielded twisted pair cable. As shown, the plug body 310 may enclose a high voltage connector 340, one or more posts 344, one or more high voltage capacitors 304, and a substrate 338 having a low voltage capacitor 306.

Optional torque features 336 (shown schematically) may include one or more grooves formed in the plug body 310, which may be in an insulating resin. The one or more recesses may be disposed laterally or radially relative to a longitudinal axis 350, the longitudinal axis 350 extending through the center of the example sensor 300 and the hexagonal torque structure 334. The one or more recesses may be sized and shaped to receive a portion of a wrench (e.g., a wrench) that may be manipulated to screw the example sensor 300 onto a threaded high voltage conductor in a separable conductor.

The plug body 310 may transfer torque from the low voltage end portion 313 to the high voltage end portion 311 to secure the sensor to the separable connector. Specifically, the plug body 310 may transmit torque between the torque structures 334, 336 and the high voltage connection 340. In some embodiments, the plug body 310 (e.g., an insulating resin) is bonded or otherwise coupled to the torque structure 334 and the high voltage connection 340. The outer surface of the torque structure 334 or the high voltage connection 340 may have a textured surface that may be formed by knurling so as to be bondable by the material of the plug body 310.

As shown, the high voltage connection 340 includes a cavity 342 for receiving and covering the high voltage conductors of the separable connector. When the example sensor 300 is inserted into the separable connector, the high voltage connection 340 may be threadably engaged onto an inner surface defining the cavity 342 and threadably coupled to the high voltage conductor.

A substrate 338 may be included to support the one or more low voltage capacitors 306 and any optional electronics. As shown, the two low voltage capacitors 306 are disposed on the substrate 338 and have different sizes. As shown, low voltage connection 330, ground connection 332, and torque structure 334 are also coupled to substrate 338. The substrate 338 may be a printed circuit board. The substrate 338 may include conductors, such as traces or wires, to facilitate mechanical connection with other components, electrical connection, or both. As shown, the conductors of the substrate 338 connect the low voltage capacitors 306 in a parallel manner. The base 338 may include through-holes to facilitate mechanical coupling to one or more of the rods 344, the ground connector 332, or both.

The exemplary sensor 300 may be mechanically assembled to include one or more discrete capacitors 304, 306. One or more rods 344 may be used to mechanically and electrically couple other components of the example sensor 300. However, any suitable mechanical and electrical coupling mechanism or combination thereof may be used. In some embodiments, the rod 344 is threaded and coupled to other components having complementary threads. In some embodiments, the rod 344 is press fit to each of the components. At least some of the components may be coupled by the rods 344 before the plug body 310 is formed around at least some of the components. For example, the high voltage connection 340, the one or more high voltage capacitors 304, the substrate 338, and the torque structure 334 may be coupled by one rod 344 disposed between each adjacent component along the longitudinal axis 350. Rod 344 provides axial and lateral stiffness to exemplary sensor 300. A plug body 310 (e.g., an insulating resin) may be formed around these components to further mechanically couple the components together. The plug body 310 may further increase stiffness in the same manner, and may also increase rotational stiffness to allow torque to be transmitted through the sensor. In some embodiments, one or more rods 344 may be secured (prevent backing off) using a polymer thread locking compound (conductive or non-conductive), a mechanical structure for locking threads, or a nylon thread locking insert, which may facilitate torque transmission through the sensor.

Fig. 7, 8, 9, and 10 illustrate different views of an exemplary sensor 400. Fig. 7 shows a perspective view of the final assembled exemplary sensor 400. Fig. 8 shows a cross-sectional view of an exemplary sensor 400. Fig. 9 shows a perspective view of a partially assembled exemplary sensor 400 without a plug body 410. Fig. 10 shows a perspective view of a partially assembled exemplary sensor 400 having a partially assembled plug body 410.

Many of the parts and components shown in fig. 7-10 are the same or similar to those shown and described with reference to the other figures described herein. For similarly numbered elements shown with reference to fig. 7-10 but not specifically discussed in detail, reference is made to the discussion regarding other figures described herein.

As shown, the exemplary sensor 400 includes: a plug main body 410; a low voltage connection 430 including a low voltage signal V for providing to an external device_LThe cable of (1); another low voltage connection 431 including a cable to receive a signal; a ground connection 432 connected to a ground signal V_G(ii) a And a torque structure 434 comprising a hexagonal protrusion. The plug body 410 is a one-piece plug body. The torque structure 434 is integrally formed into the plug body 410 and may be formed from the same material as the plug body. Exemplary sensor 400 may include a torque structure including one or more recesses (not shown here) in the plug body. In another embodiment, the torque structure 434 may be formed of a conductive or semi-conductive material, or may include a conductive or semi-conductive material within an insulating resin or similar material.

The plug body 410 may extend from the high voltage end portion 411 to the low voltage end portion 413. The cables of the low voltage connections 430, 431 may extend from the low voltage end portion 413. As shown, the cable may be similar to the cable of the example sensor 300, but may be terminated, for example, by a receptacle. As shown, the plug body 410 may enclose a high voltage connection 440, one or more rods 444, one or more high voltage capacitors 404, a first substrate 438 having low voltage capacitors, and a second substrate 439 having electronics (e.g., signal conditioning electronics).

The intermediate ground connector 433 may mechanically and electrically couple the first substrate 438 to the second substrate 439. The ground connection 432 may be electrically coupled to the intermediate ground connection 433.

The low voltage connections 430, 431 may comprise the same type of cable. The low voltage connection 431 can be connected to a device and receive a signal, for example from a Rogowski coil. The signal from the Rogowski coil may correspond to the current signal present in the separable connector and may be described as a current path. The signal may be purified before passing through the low voltage connection 430. The sensor 102 may condition a signal corresponding to the current signal and combine the voltage and current paths into a single multi-conductor cable for connection to the RTU. The memory is also accessible through the low voltage connection 430.

In some embodiments, the plug body 410 may be formed from multiple streams of resin. The first fluence may encapsulate the high voltage connection 440, the one or more high voltage capacitors 404, and the first substrate 438 (fig. 10). The second fluence may encapsulate the second baseplate 439 to form a final assembled exemplary sensor 400 (fig. 7).

Fig. 11 and 12 show different views of an exemplary sensor 500. Fig. 11 shows a cross-sectional view of an exemplary sensor 500. Fig. 12 shows a cut-away perspective end view of an exemplary sensor 500.

Many of the parts and components shown in fig. 11 and 12 are the same as or similar to those shown and described with reference to the other figures described herein. For similarly numbered elements shown with reference to fig. 11 and 12 but not specifically discussed in detail, reference is made to the discussion regarding other figures described herein.

As shown, the exemplary sensor 500 includes: a plug main body 510; one or more high voltage capacitors 504; a low voltage connection 530 providing a low voltage signal V to an external device_L(ii) a A ground connection 432 connected to the ground V_G(ii) a A torque feature 534 comprising a hex-shaped protrusion; a high voltage connection 540; and one or more rods 544 connected to other components of the sensor. As shown, more than one high voltage capacitor 504 is connected in series. The plug body 410 is a separable plug body. The torque structure 434 is formed separately from the resin of the plug body and may be electrically conductive.

The plug body 510 may extend from a high voltage end portion 511 to a low voltage end portion 513, the low voltage end portion 513 being connectable to and disconnectable from the high voltage end portion. The low-voltage end portion 513 may be an insulating cap that is detachably connected to the high-voltage end portion 511, similar to the form of the insulating cap 106. The torque structure 534 may be disposed at one end of the high voltage end portion 511. The intermediate connection 541 may form an electrical connection, a mechanical connection, or both with the torque structure 534. The intermediate connector 541 may be a spring contact, such as a pogo pin, and may include an insulating support to couple to the base plate 538. Low voltage end portion 513 may support substrate 538 and low voltage connection 530. The base plate 538 may support the intermediate connection 541. Substrate 538 may support electronics such as signal conditioning electronics that provide a conditioned voltage signal V through low voltage connection 430 or another connection_C。

The exemplary sensor configurations described herein may be used in a variety of different separable connector products, including shielded terminals, in particular, base insulated plugs or dead-end plugs. Further, sensors and products comprising such sensors may be used in networks such as power grid networks.

Accordingly, embodiments of a sensor with a discrete capacitor for a high voltage separable connector are disclosed. Those skilled in the art will appreciate that various adaptations and modifications of the exemplary embodiments and alternative embodiments described herein may be configured without departing from the scope and spirit of the invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. For example, the exemplary embodiments described herein may be combined with each other in various ways.

All references and publications cited herein are expressly incorporated by reference in their entirety into this disclosure, except to the extent that they may directly conflict with this disclosure.

Unless defined otherwise, all scientific and technical terms used herein have the same meaning as commonly understood in the art. The definitions provided herein will facilitate understanding of certain terms used frequently herein and are not meant to limit the scope of the present disclosure.

Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range. Herein, the term "up to" or "not more than" a numerical value (e.g., up to 50) includes the numerical value (e.g., 50), and the term "not less than" a numerical value (e.g., not less than 5) includes the numerical value (e.g., 5).

Orientation-related terms such as "end" are used to describe relative positions of components and are not intended to limit the orientation of the contemplated embodiments.

Reference to "one embodiment," "an embodiment," "certain embodiments," or "some embodiments," etc., means that a particular structure, configuration, composition, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of such phrases in various places throughout this disclosure are not necessarily referring to the same embodiment of the disclosure. Furthermore, the particular structures, configurations, compositions, or characteristics may be combined in any suitable manner in one or more embodiments.

As used in this specification and the appended claims, the singular forms "a", "an", and "the" encompass embodiments having plural referents, unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term "or" is generally employed in its sense including "and/or" unless the context clearly dictates otherwise.

As used herein, "having," including, "" comprising, "and the like are used in their open sense and generally mean" including, but not limited to. It is to be understood that "consisting essentially of", "consisting of", and the like are encompassed by the term "comprising" and the like.

The term "and/or" refers to one or all of the listed elements or a combination of any two or more of the listed elements (e.g., casting and/or processing an alloy refers to casting, processing, or both casting and processing an alloy).

The phrases "at least one (kind) in … …", "at least one (kind) in … …", and "one (kind) or more (kinds) in … …" of the following list refer to any one of the items in the list and any combination of two or more of the items in the list.