SYSTEM AND METHOD FOR SENSING VOLTAGE IN MEDIUM-TO-HIGH
VOLTAGE APPLICATIONS
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to voltage sensors for use with line
conductors and, more particularly, to a compact capacitive divider-type sensor that is
easy to manufacture and capable of measuring the potential of a medium-to-high
voltage line conductor.
[0002] Capacitive divider-type sensors measure the AC voltage of a line conductor
or bus bar. In such a device, a first capacitor (CI) with a known capacitance is
connected to the line conductor. A second capacitor (C2) with a capacitance larger than
the first is connected in series between CI and ground. The voltage (Vc2) across C2 is
proportional to the line voltage (Vl) between the line conductor and ground..
Specifically, VL may be determined using the following equation:
Vc2=VL(Cl/(Cl+C2)).
[0003] When constructing a capacitive divider capable of measuring voltage in
medium voltage (MV) to high voltage (HV) applications (e.g., approximately 1 kV to
50 kV), numerous design factors are typically taken into account. For example, both CI
and C2 are typically constructed using a number of individual capacitors to reduce the
voltage on both C1 and C2 to a value that is within each capacitor's voltage rating.
Such individual components, however, significantly increase complexity, inaccuracy
possibilities, and manufacturing costs to the capacitive divider.
[0004] Also, the electric field (E-field) concentration on individual components of
the capacitive divider influences the design of the capacitive divider. As is known, E-
field concentration is, in part, a factor of the voltage of the line conductor. That is, as
the voltage of the line conductor increases, E-field concentration on the individual
components of the capacitive divider may increase as well. When E-field concentration
is high, dielectric breakdown may occur between the line conductor and the voltage
sensor. While E-field concentration may be minimized by increasing the distance

between individual components of the capacitive divider, such an increase in component
spacing also increases the overall size of the device.
[0005] It would therefore be desirable to design an apparatus and method for
measuring the voltage of a medium-to-high voltage line conductor that is small,
accurate, and relatively inexpensive to manufacture.

BRIEF DESCRIPTION OF THE INVENTION
[0006] The present invention provides a system and method for sensing the voltage
of a medium or high voltage line conductor. Therefore, in accordance with one aspect
of the present invention, a voltage sensor for a line conductor includes an electrical
insulator comprising a surface and an edge, the surface having a length and the edge
having a thickness defining a thickness of the electrical insulator. The length of the
surface of the electrical insulator is substantially greater than the thickness of the edge.
The surface of the electrical insulator has an opening therein to allow passage of a line
conductor therethrough in a direction generally perpendicular to the surface. The
voltage sensor also includes first and second electrodes positioned about the opening
on the surface of the electrical insulator and spaced apart from one another to provide a
common capacitive divider signal indicative of a voltage potential of the line conductor.
[0007] In accordance with another aspect of the invention, a method of
manufacturing a line sensor includes providing an insulating substrate having an
attachment surface and having an opening therein to allow a line conductor to pass
through in a direction generally perpendicular to the attachment surface. The method
also includes coupling first and second electrodes of an electrode assembly to the
attachment surface of the insulating substrate, spacing the first and second electrodes of
the electrode assembly apart from one another on the insulating substrate, and
configuring the electrode assembly to output a signal indicative of a voltage potential of
the line conductor.
[0008] In accordance with yet another aspect of the invention, a voltage sensor for a
line conductor includes an electrically insulating substrate having a contact surface, the
contact surface having an opening sized to allow a line conductor to pass therethrough
in a direction generally perpendicular to the contact surface. The line conductor also
includes a sensor electrode coupled to the contact surface of the electrically insulating
substrate and a grounded electrode coupled to the contact surface of the electrically
insulating substrate. The sensor electrode and the grounded electrode form elements of
a capacitive divider and produce a common output.

[0009] Various other features and advantages of the present invention will be made
apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The drawings illustrate preferred embodiments presently contemplated for
carrying out the invention
[0011] In the drawings:
[0012] FIG. I is a perspective view of a voltage sensor according to an embodiment
of the invention.
[0013] FIG. 2 is a cross-sectional view of the voltage sensor of FIG. 1.
[0014] FIG. 3 is an equivalent circuit of a capacitive divider according to an
embodiment of the invention.
[0015] FIG. 4 is a cross-sectional view of a voltage sensor according to another
embodiment of the invention.
[0016] FIG. 5 is a cross-sectional view of a sensor assembly according to an
embodiment of the invention.

DETAILED DESCRIPTION
[0017) The embodiments of the invention set forth herein relate to a system and
method for sensing voltage of a medium or high voltage line conductor. In one
embodiment, the invention is implemented with a voltage sensor having two capacitors
in series formed therein. A voltage sensor 10 is shown in FIG. 1 and includes a
grounded voltage sensor shield 12, which may be constructed of injected-molded plastic
plated with a metal, such as, for example, nickel and/or copper. Other alternatives
include stamped metal, a metal mesh/screen, or a combination of the aforementioned
materials. Sensor shield 12 is a faraday shield having a generally circular shape. In one
embodiment, sensor shield 12 may be constructed having a top shield 14 and a bottom
shield 16 fastened together with rivets 18. An electrical insulator or electrically
insulating substrate 20 having a generally disk shape is positioned between top and
bottom shields 14, 16. Electrical insulator 20 has an opening 22 therein to receive a line
conductor (not shown in FIG. 1). In a preferred embodiment, electrical insulator 20 is a
printed circuit board (PCB). Alternatively, electrical insulator 20 may be a thin
(approximately 0.002 in), insulated support sheet comprising a material such as, for
example, Kapton.
[0018J A first or sensor electrode 24 and a second or grounded electrode 26 are
affixed to or formed on support plate 20 about the opening of 22 electrical insulator 20.
In one embodiment, first and second electrodes 24, 26 are formed using a printing,
painting, electro-deposition, or metal spraying process to deposit a layer of conductive
material such as copper, for example, on electrical insulator 20. Wired connection 28
connects first electrode 24 to a contact pad 30 of a readout circuit 32, which will be
described in more detail with respect to FIGS. 2 and 3. Wired connection 34 connects
second electrode 26 to grounded voltage sensor shield 12.
[0019] As shown in FIG. 1, radius corners or edge portions 36, 38 of top and bottom
shields 14, 16 have a curved profile, which minimizes electric-field concentration and
arcing on edge portions 36, 38 and helps to prevent dielectric breakdown. Alternatively,
curled edge portions 36, 38 may be formed by attaching a large diameter wire ring to
top and bottom shields 14, 16. The curvature of edge portion 36, 38 also allows first

and second electrodes 24, 26 to be placed closer to a line conductor, therefore
decreasing the overall size of voltage sensor 10.
[0020] Referring now to FIG. 2, a cross-sectional view of a voltage sensor 40 is
shown according to one embodiment of the invention. Voltage sensor 40 includes a
shield assembly 42 having a first shield 44 and a second shield 46 connected to ground
48. A printed circuit board (PCB) 50 is positioned between first shield 44 and second
shield 46, PCB 50 has a top edge 52, a bottom edge 54, a first side surface or
attachment surface 56, and a second side surface or attachment surface 58. As shown in
FIG. 2, PCB 50 has an overall length 60 much larger than a thickness 62 thereof. An
opening 64 in PCB 50 allows a line conductor 66 to pass therethrough. PCB 50 is
positioned such that top edge 52 and bottom edge 54 are oriented substantially parallel
to a central axis 68 of line conductor 66. First side surface 56 and second, side surface
58 of PCB 50 are oriented substantially perpendicular to centra] axis 68 of line
conductor 66 and have respective contact locations 70, 72 and a number of respective
non-contact locations 74, 76 positioned thereon. A sensor electrode 78 is affixed to. first
side surface 56 of PCB 50 at contact location 70, and a grounded electrode 80 is affixed
to second side surface 58 of PCB 50 at contact location 72. As shown in FIG. 2, sensor
electrode 78 and grounded electrode 80 are located equidistant to opening 64 of PCB 50
and line conductor 66. Alternatively, electrodes 78, 80 may be offset from each other
on PCB 50 such that one of sensor electrode 78 and grounded electrode 80 is closer to
line conductor 66 than the other.
[0021] Also affixed to PCB 50 is a readout circuit 82 having a contact pad 84
positioned thereon. Sensor wire 86 electrically connects sensor electrode 78 to contact
pad 84. Ground wire 88 grounds electrode 80 via a connection to first shield 44.
Readout circuit 82 buffers the high impedance of voltage sensor 40 and includes a
buffer and amplifier circuit 90 to amplify signals from sensor electrode 78 for a voltage
sensor output 92. Because dielectric constants are temperature sensitive, a
thermocouple 94 and a microprocessor 96 may also be included on readout circuit 82
such that a dielectric constant may be corrected as a function of temperature.

[0022] A schematic circuit diagram of voltage sensor embodiments of the invention
is shown in FIG. 3. Referring FIGS. 2 and 3, a capacitive divider 98 is formed between
line conductor 66, sensor electrode 78, and grounded electrode 80. A first capacitor
(CI) 100 is formed between line conductor (VL) 66 and sensor electrode 78. As is
known, the capacitance of CI 100 m^v h~ controlled by selectively sizing sensor
electrode 78 and setting the distance between sensor electrode 78 and line conductor 66.
In one embodiment, the capacitance of CI 100 may be approximately 10 fF. . A second
capacitor (C2) 102 is formed between sensor electrode 78 and grounded electrode 80.
Similar to that explained with respect to CI 100, the capacitance of C2 102 may be
selected based on the size and position of both sensor electrode 78 and grounded
electrode 80. In one embodiment, the capacitance of C2 102 may be approximately 100
pF. A buffer and amplifier circuit 90 mounted on readout circuit 82 amplifies a sensed
voltage potential signal 104 proportional to the sensed voltage from capacitive divider
98 and transmits a signal indicative of a voltage potential of line conductor 66 to an
external trip unit (not shown). In one embodiment, the ratio between the sensed
voltage signal 104 and VL 66 is 1:10,000 or lOOmV/kV.
[0023] FIG. 4 shows a cross-section of a voltage sensor 106 according to another
embodiment of the invention.. A sensor shield or shield ring 108 is connected to ground
110 and forms a continuous piece of metal or metal-plated plastic that surrounds a PCB
112. PCB 112 has a passage 114 formed therein to receive a line conductor 116. An
electrode assembly 118 comprising a sensor electrode 120 and a grounded electrode 122
are positioned on a common planar contact surface 124 of PCB 112. Wired connection
126 grounds electrode 122 via a connection to grounded shield ring 108. Wired
connection 128 electrically connects to contact pad 130 of a readout circuit 132.
[0024] As shown in FIG. 5 according to one embodiment of the invention, a voltage
sensor 134 may be incorporated within a sensor assembly 136. Voltage sensor 134
includes a voltage shield or housing 138, a PCB 140, and first and second electrodes
142, 144. In addition to voltage sensor 134, sensor assembly 136 also includes a current
sensor assembly 146 having a housing or shield 148 to prevent dielectric breakdown
from a line conductor 150. Shield 148 surrounds a current sensor 152 and first and

second parasitic power current transformers (CT) 154, 156. Accordingly to one
embodiment, current sensor 152 is a Rogowski coil that detects the current in line
conductor 150. CTs 154, 156 parasitically generate power from either the line current
or line voltage and provide power to voltage sensor 134 and to the external trip unit (not
shown).
[0025] Voltage sensor 134 and current sensor assembly 146 are positioned in a
housing or common structure 158 with spacers 160. While spacers 160 are shown as
solid cylinders, alternate embodiments may only have a few minimal support points for
equal effectiveness. A passage 162 in housing 158 is sized to receive line conductor
150. Wired connections 164, 166 from vunage sensor 134 and current sensor assembly
146, respectively, connect to a multi-pin connector 168, which allows transmission of
sensor signals from the voltage sensor 134 and current sensor 152 to an external trip
unit (not shown).
[0026] In one embodiment, an insulating material or encapsulant 170, such as an
epoxy with a high dielectric breakdown strength, for example, forms a dielectric within
housing 158. Insulating material 170 minimizes dielectric breakdown between line
conductor 150 and the shields 138, 148, and also between voltage sensor 134 and
current sensor assembly 146. Insulating material 170 is injected into housing 158 to
encapsulate voltage sensor 134 and current sensor assembly 146 and fill any air gaps
within voltage sensor 134 and current sensor assembly 146. Vent holes 172 in both
current shield 148 and voltage shield 138 allow air to escape during encapsulation.
[0027] Therefore, in accordance with one aspect of the present invention, a voltage
sensor for a line conductor includes an electrical insulator comprising a surface and an
edge, the surface having a length and the edge having a thickness defining a thickness of
the electrical insulator. The length of the surface of the electrical insulator is
substantially greater than the thickness of the edge. The surface of the electrical
insulator has an opening therein to allow passage of a line conductor therethrough in a
direction generally perpendicular to the surface. The voltage sensor also includes first
and second electrodes positioned about the opening on the surface of the electrical

insulator and spaced apart from one another to provide a common capacitive divider
signal indicative of a voltage potential of the line conductor.
[0028] In accordance with another aspect of the invention, a method of
manufacturing a line sensor includes providing an insulating substrate having an
attachment surface and having an opening therein to allow a line conductor to pass
through in a direction generally perpendicular to the attachment surface. The method
also includes coupling first and second electrodes of an electrode assembly to the
attachment surface of the insulating substrate, spacing the first and second electrodes of
the electrode assembly apart from one another on the insulating substrate, and
configuring the electrode assembly to output a signal indicative of a voltage potential of
the line conductor.
[0029] In accordance with yet another aspect of the invention, a voltage sensor for a
line conductor includes an electrically insulating substrate having a contact surface, the
contact surface having an opening sized to allow a line conductor to pass therethrough
in a direction generally perpendicular to the contact surface. The line conductor also
includes a sensor electrode coupled to the contact surface of the electrically insulating
substrate and a grounded electrode coupled to the contact surface of the electrically
insulating substrate. The sensor electrode and the grounded electrode form elements of
a capacitive divider and produce a common output.
[0030] The present invention has been described in terms of the preferred
embodiment, and it is recognized that equivalents, alternatives, and modifications, aside
from those expressly stated, are possible and within the scope of the appending claims.

What is claimed is:
1. A voltage sensor for a line conductor comprising:
an electrical insulator comprising a surface and an edge, the surface
having a length and the edge having a thickness defining a thickness of the electrical
insulator, wherein.the length of the surface is substantially greater than the thickness of
the edge, the surface of the electrical insulator having an opening therein to allow
passage of a line conductor therethrough in a direction generally perpendicular to the
surface; and
first and second electrodes positioned about the opening on the surface of
the electrical insulator and spaced apart from one another to provide a common
capacitive divider signal indicative of a voltage potential of the line conductor.
2. The voltage sensor of claim 1 wherein the electrical insulator has two
surfaces, each having thereon a respective electrode.
3. The voltage sensor of claim 2 wherein the first electrode and the second
electrode are positioned equidistant to the line conductor.
4. The voltage sensor of claim 1 wherein both first and second electrodes
are on a common planar surface.
5. The voltage sensor of claim 1 further comprising a buffer and amplifier
circuit, and wherein the first electrode is connected to the buffer and the amplifier
circuit and the second electrode is connected to a common ground.
6. The voltage sensor of claim 1 wherein the first electrode is positioned at
a first distance from the line conductor and the second electrode is positioned at a
second distance from the line conductor different from the first distance.

7. The voltage sensor of claim 1 further comprising a housing positioned
about the electrical insulator and the first and second electrodes.
8. The voltage sensor of claim 7 further comprising a current sensor
integrated into a common structure with the voltage sensor.
9. The voltage sensor of claim 7 wherein the housing is at gro.und potential
and has radius corners, thereby providing arc reduction between the line conductor and
the housing, and has a dielectric between the voltage sensor and the housing.
10. A method of manufacturing a line sensor comprising:
providing an insulating substrate having an attachment surface and
having an opening therein to allow a line conductor to pass through in a direction
generally perpendicular to the attachment surface;
coupling first and second electrodes of an electrode assembly to the
attachment surface of the insulating substrate;
spacing the first and second electrodes of the electrode assembly apart
from one another on the insulating substrate; and
configuring the electrode assembly to output a signal indicative of a
voltage potential of the line conductor.
11. The method of claim 10 wherein spacing the first and second electrodes
apart from one another on the attachment surface comprises positioning the first and
second electrodes on a common attachment surface.
12. The method of claim 10 wherein spacing the first and second electrodes
apart from one another on the attachment surface comprises positioning the first and
second electrodes equidistant to the opening of the attachment surface.

13. The method of claim 10 further comprising positioning a housing about
the insulating substrate and the electrode assembly.
14. The method of claim 13 further comprising positioning a common
structure about the housing.
15. The method of claim 14 further comprising injecting an encapsulant
between the housing and the common structure.
16. The method of claim 15 further comprising ventilating air from within
the common structure when injecting the cncapsulant.
17. The method of claim 14 further comprising positioning a current sensor
within the housing.
18. The method of claim 10 further comprising configuring a readout circuit
to output the signal indicative of a voltage potential of the line conductor.
19. A voltage sensor for a line conductor comprising:
an electrically insulating substrate having a contact surface, the contact
surface having an opening sized to allow a line conductor to pass therethrough in a
direction generally perpendicular to the contact surface;
a sensor electrode coupled to the contact surface of the electrically
insulating substrate;
a grounded electrode coupled to the contact surface of the electrically
insulating substTate; and
wherein the sensor electrode and the grounded electrode form elements
of a capacitivc divider and produce a common output.

20. The voltage sensor of claim 19 further comprising a grounded shield ring
substantially surrounding the electrically insulating substrate, the sensor electrode, and
the grounded electrode.
21.... The voltage sensor of claim 20 wherein the grounded shield ring has
curved surface contours to reduce arcing between the line conductor and the grounded
shield ring.
22. The voltage sensor of claim 19 wherein the electrically insulating
substrate is a printed circuit board and has a generally disk shape.
23. The voltage sensor of claim 22 further comprising a readout circuit
coupled to the electrically insulating substrate and configured to output a signal
indicating a voltage potential of the line conductor.

A system and method for measuring voltage of a medium to high voltage line
conductor is disclosed. The system includes an electrical insulator having a surface and
an edge, the surface having an opening therein to allow passage of a line conductor
therethrough in a direction generally perpendicular to the surface. The system also
includes first and second electrodes positioned about the opening on the surface of the
electrical insulator and spaced apart from one another to provide a common capacitive
divider signal indicative of a voltage potential of the line conductor.