Realization of wide range of current transformer based on Permalloy core

Current transformers based on Permalloy cores have the advantages of high sensitivity and low hysteresis losses, making them ideal for use in wide-range applications. There are several key aspects to consider when implementing a wide-range current transformer:

1. Core material selection

The high permeability and low losses of Permalloy cores make them very sensitive when measuring smaller currents. However, for large current measurements, it is also necessary to ensure that the core is not saturated, so the appropriate core size and shape need to be selected.

2. Core size and shape

Selecting the appropriate core size and shape ensures that current can be effectively measured over the entire range. Larger cores can handle larger currents, but core saturation should be avoided.

3. Multi-level transformer design

To achieve a wide range, a multi-level transformer can be designed, that is, multiple windings are integrated in one transformer, each for a different current range. The different current ranges can be accommodated by electronic switching or paralleling multiple windings.

4. Compensation circuit

The use of compensation circuits can improve the linearity and accuracy of the transformer over a wide range. For example, operational amplifiers can be used for signal conditioning to reduce nonlinear errors.

5. Digital signal processing

Combined with digital signal processing technology, the measurement accuracy and dynamic range of the transformer can be further improved by filtering, amplifying and correcting the measurement signal.

6. Calibration and testing

Regularly calibrate the transformer to ensure its accuracy and stability over the entire range. Use standard calibration equipment and methods to verify and adjust the performance of the transformer.

Implementation example

The following are the design steps for a wide-range current transformer based on a Permalloy core:

1. Select the core: Select a Permalloy core with high magnetic permeability and suitable for wide-range applications. For example, use a C-type or toroidal core with a suitable cross-sectional area and length.

2. Design the primary and secondary windings: Design the primary and secondary windings according to the expected current range. Ensure that the secondary winding can effectively sense the flux changes of the primary winding.

3. Multi-level winding design: Integrate multiple secondary windings in the transformer, each corresponding to a different current range. Use an electronic switch or multiplexer to select the appropriate winding.

4. Signal conditioning circuit: Design a signal conditioning circuit, use operational amplifiers and filters to process the sensing signal, and improve the linearity and signal-to-noise ratio of the signal.

5. Digital processing module: Combined with a microcontroller or digital signal processor, the conditioned signal is sampled, processed and corrected. Automatic range switching and digital output can be achieved.

6. Calibration and testing: Use a standard current source to calibrate the transformer to ensure its accuracy throughout the range. Verify the effectiveness of the design through experimental tests, and adjust and optimize it according to the test results.

Through the above steps, a wide-range current transformer based on Permalloy core can be designed and implemented, which is suitable for various current measurement applications with high precision and wide dynamic range.