Direct-Write Printed Current Sensor for Load Monitoring Applications

Yongchao Yu, Aravind K. Mikkilineni, Stephen M. Killough, Teja Kuruganti, Pooran C. Joshi, Anming Hu

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

1 Scopus citations

Abstract

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-\boldsymbol{\mu} \mathbf{m}-thick permalloy film. The overall thickness of the polyimide substrate and permalloy sheet remains well-below 500\ \boldsymbol{\mu} \mathbf{m} 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.

Original languageEnglish
Title of host publication2019 IEEE Power and Energy Society Innovative Smart Grid Technologies Conference, ISGT 2019
PublisherInstitute of Electrical and Electronics Engineers Inc.
ISBN (Electronic)9781538682326
DOIs
StatePublished - Feb 2019
Event2019 IEEE Power and Energy Society Innovative Smart Grid Technologies Conference, ISGT 2019 - Washington, United States
Duration: Feb 18 2019Feb 21 2019

Publication series

Name2019 IEEE Power and Energy Society Innovative Smart Grid Technologies Conference, ISGT 2019

Conference

Conference2019 IEEE Power and Energy Society Innovative Smart Grid Technologies Conference, ISGT 2019
Country/TerritoryUnited States
CityWashington
Period02/18/1902/21/19

Funding

This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. This material is based upon work supported by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

Keywords

  • additive manufacturing
  • current sensor
  • flexible electronics
  • printed sensor

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