Direct-Write Printed Current Sensor for Load Monitoring Applications
We report on a flexible current sensor development employing direct-write printing and additive manufacturing techniques. The integrated current sensor unit incorporates sensing, data processing & storage, and in-field calibration capabilities. A combination of direct-write printing technique and low-temperature curable metallic ink is used to print Ag wires around a 12.5-μm -thick permalloy film. The overall thickness of the polyimide substrate and permalloy sheet remains well-below 500 μm enabling wrap-around sensor functionality. Fused deposition modeling (FDM) additive manufacturing is used to build custom parts for sensor mounting, encapsulation, and an in-field calibration unit using heat and chemical-resistant thermoplastic which responds well to mechanical stress. In the present configuration, the integrated current sensor unit can be powered through USB or 4 AAA batteries to allow data collection and sensor calibration in the field. The flexible current sensor employing a continuous sheet of the permalloy exhibited a well-behaved signal output response at peak current levels exceeding 15A and in the applied ac frequency range of 60 Hz–10 kHz. Overall, the combination of direct-write printing, thin permalloy material, and additive manufacturing technique shows promise for the development of a reconfigurable low-cost current sensor that can be deployed in large numbers at locations of interest to avail the cost and energy-saving opportunities in industrial/commercial and residential applications.
- Research Organization:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- AC05-00OR22725
- OSTI ID:
- 1559587
- Resource Relation:
- Conference: 2019 IEEE Power & Energy Society Innovative Smart Grid Technologies Conference (ISGT 2019) , Washington, DC, District of Columbia, United States of America, 2/18/2019-2/21/2019
- Country of Publication:
- United States
- Language:
- English
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