Design and Optimization Methods of the Header of HDI PCB Rogowski Current Sensors

Abstract

Printed circuit board (PCB)-based headers of Rogowski current sensors (HRCSs) have garnered growing interest from researchers in recent years, and they have been widely applied in many electrical scenarios due to their advanced features, such as nondeformable volume, flexible shape and size, and low cost. The determination of PCB HRCS parameters mainly depends on a time-consuming finite-element simulation, but these simulations cannot be used to calculate PCB HRCSs with a complex irregular structure or high-density thin winding wire. This article presents a method to calculate a PCB HRCS to address complex irregular structures and high-density thin winding wire. Furthermore, because it does not involve the time-consuming meshing process, this method is relatively fast. Taking two HRCSs with a given complex structure and thin winding wire as examples, we used the proposed method to determine its sensitivity, anti-interference characteristics, and the influence of the obtained internal parasitic capacitance and inductance parameters on the measured output voltage. Moreover, the optimal structural parameters of these PCB HRCSs are discussed when the installation space and the cross section of the measured conductor are given. The results of the high-density PCB HRCS experiments verify the proposed method.