The customer wanted to reduce the overall cost of cabling by switching from copper to aluminium. The aluminium conductor would involve a large inner diameter for the primary conductor without changing the overall size of the sensor.

PCB size reduced and less area for assembly, same component count. Higher temperature rise. Coil construction smaller core overall. Large inner diameter. Winding constraints.

Electrohms developed an entirely new electrical and mechanical design with new processes to wind the coil to create a sensor with a smaller overall size. We had to model thermal characteristics and deliver an improved thermal design to ensure reliable sensor performance. Using a range of design tools and proven rapid prototyping processes Electrohms designed and developed the samples on time, meeting system performance requirements. Electrohms offered the customer an entirely new design which provided better value for their system.