The Kynix Blog

Ⅰ IntroductionA differential transformer is an electromagnetic inductive displacement sensor that converts mechanical displacement into an electrical signal. It mainly relies on the displacement of the movable iron core in the cylindrical coil and establishes a mutual induction relationship between the input coil and the output coil of the cylindrical coil, and the displacement of the movable core can be obtained by measuring the induced voltage of the output coil proportional to it.  CatalogⅠ IntroductionⅡ The Working Principle and Structure of the Differential TransformerⅢ The Type of Differential TransformerⅣ Linearity and SensitivityⅤ The Cause of the ErrorⅥ The Measurement Circuit  6.1 Differential DC output circuit  6.2 DC differential transformer circuitⅦ The Application of Differential TransformerⅧ Application Circuit Examples of Differential Transformer  8.1 MZK-4R Grinding Machine Automatic Control Device  8.2 ZD41B Short Cylindrical Roller Sorting Machine  8.3 Discussion of Differential Transformer ApplicationⅨ FAQ Characteristics of Differential Transformer(1) There are many types of linear ranges, and it is easy to select according to the use. Usually, there are about 10 types between ±2 mm and ±200 mm.(2) The structure is simple, so the vibration resistance and impact resistance are strong.(3) It does not wear, does not deteriorate, and has excellent durability.(4) The output voltage has a precise ratio to the displacement of the core, that is, the linearity is good. Generally, the full stroke deviation of this sensor is less than 1%, and it can be guaranteed to be ±0.2% to ±0.3% in high-grade products.(5) Because of the high sensitivity, a large output voltage can be obtained, and a small displacement can be detected without requiring an advanced circuit.(6) Since the output changes smoothly, high-resolution detection is possible.(7) The zero point is stable, and its use as a reference point for measurement is good for maintaining accuracy.(8) A high response speed from 500 Hz to 100 Hz can be obtained. Ⅱ The Working Principle and Structure of the Differential TransformerThe structure of the differential transformer is divided into two types: variable-gap type and solenoid type. Since the variable-gap type differential transformer has a small stroke and a complicated structure, it is rarely used at present, and the solenoid type is usually adopted. The basic components of the solenoid type differential transformer include an armature, a primary coil, a secondary coil, and a coil frame. The primary coil acts as excitation and corresponds to the primary side of the transformer. The secondary coil is formed by inverting two coils of the same structural size and parameters to form the secondary side of the transformer. There are two-section, three-section and multi-section according to the initial and secondary arrangement. The zero potential of the three-section is small, the two-section is more sensitive than the three-section, and the linear range is large. The four-section and five-section are all efforts to improve the linearity of the sensor. The working principle of the differential transformer can be explained by the principle of the transformer. The difference is: the general transformer is the closed magnetic circuit, and the differential transformer is the open magnetic circuit; the mutual inductance of the original transformer and the secondary side is constant, and the mutual inductance between the primary and secondary sides of the differential transformer changes as the armature moves. The operation of the differential transformer is based on the change of mutual inductance. The construction principle of the differential transformer is as shown in figure 1, and is composed of a cylindrical coil and a core that is completely separated from it. A typical differential transformer has three cylindrical coils, each of which is one-third of the total length, with a primary coil in the middle and a secondary coil on each side. The iron core added to the cylindrical coil is used to link the magnetic lines of force in the coil to form a magnetic circuit. Figure 1. The Construction Principle of the Differential Transformer When an alternating voltage is applied to the primary coil in the middle (ie, excitation), an electromotive force is generated due to the mutual inductance with the coils at both ends (this is the same as that of a normal transformer). Since the secondary coils are connected in series with each other in opposite polarity, the induced electromotive forces in the two secondary coils are opposite in phase, and as a result of the addition, a potential difference between the two is generated at the output end. At the center of the coil length direction, the induced voltages of the two secondary coils are equal in opposite directions, and thus the output is zero. This position is called the mechanical zero point of the differential transformer (or simply zero points). When the iron core changes position from zero points to a certain direction, the voltage of the secondary coil in the displacement direction increases, and the voltage of the other secondary coil decreases. The product design guarantees that the potential difference is proportional to the displacement of the core. When the iron core moves from zero points to the opposite direction, a proportional voltage is generated, but the phase is 180° different from the previous one. The relationship between the secondary coil voltage and the output voltage difference with respect to the core displacement is shown in figure 2. The range in which the voltage difference is proportional to the core displacement is called the linear range, and its proportionality is called linearity, which is the most important indicator of the differential transformer. Figure 2. The Core Displacement — Output Relationship of Differential Transformer Ⅲ The Type of Differential TransformerThe standard differential transformer consists of a cylindrical coil and a rod-shaped iron core. In actual use, there is also a structure with a guide and a spring. The basis for the classification of differential transformers is as follows: • According to the voltage input to the primary coil(excitation type)Commercial power supply type is suitable for practical measuring instruments of 50-60Hz, 6.3V power supply excitation;Oscillation power supply type is an excitation circuit of 1~5KHz, it is suitable for application measuring instruments requiring certain accuracy and response characteristics;DC power supply type, the semiconductor device is installed in the coil part of the differential transformer to form the excitation oscillation circuit and the secondary output detection circuit inside the coil. It is a differential transformer whose input and output are both DC, called DC-DT. • According to the displacement range of the iron core (displacement type)Small displacement type considers how to measure the small displacement below 0.5mm from the structure;General displacement type is designed for measuring the displacement about 100mm or less;The long-stroke type is designed for long stroke measurement of 120 to 400 mm.  • According to the use environment (environment type)Standard type is used in a normal environment with a temperature of -30℃ to +90℃ and a humidity of about 80%;Environmentally friendly type is the sensor for high temperature, high humidity, waterproof and radioactive environments. Features and SpecificationsWhen using a differential transformer as a position sensor, the selected specifications are as follows:◆ Excitation power supply (frequency, voltage, waveform, etc.);◆ Structure (whether guides and springs are required);◆ Linear range (it is usually ±1%, and that of high-grade products is ±0.5%～±0.2%);◆ Sensitivity (corresponding to the output of the core displacement of 1mm);◆ Impedance (input, output impedance);◆ Connection conditions (cables, sockets, input circuits, etc.);◆ Assembly method (connection method with the object to be tested, etc.);◆Environmental conditions (temperature, humidity, dust, water resistance, rust-proof conditions, etc.). Ⅳ Linearity and Sensitivity• Linearity. The linear range of the differential transformer is affected by the non-uniform magnetic field of the solenoid coil. A reasonable design guarantees the required linear range and linearity.• Sensitivity. The sensitivity of the differential transformer refers to the change of the output potential generated by the armature unit displacement. It can be expressed by mV/mm. In practice, considering the influence of the excitation voltage, it is also commonly expressed by mV/mm/V, that is, the potential change generated by the armature unit displacement divided by the excitation voltage value. The sensitivity of the differential transformer is related to the primary voltage, the number of secondary winding turns, and the frequency of the excitation voltage:• Relationship with secondary turnsThe number of secondary turns increases and the sensitivity increases, which is linear. However, the number of secondary turns cannot be increased indefinitely because the residual voltage at the zero points of the differential transformer also increases.• Primary voltageThe sensitivity is proportional to the primary voltage, but the primary voltage should not be too large. When the voltage is too large, the differential transformer coil will heat up and cause the output signal to drift. Generally, 3~8V is used.• Excitation power frequencyWhen the frequency is very low, the sensitivity increases with increasing frequency; when the frequency increases, the inductance of the coil is much higher than its resistance, the sensitivity is independent of the frequency; when the frequency exceeds a certain value (the value varies depending on the armature material), the effective resistance of the wire increases due to the skin effect of the wire at a high frequency, and the eddy current loss and hysteresis loss of the armature increase, and the output decreases. Figure 3 is the relationship between the input frequency and sensitivity of a certain magnetically permeable material, which can be used as a reference for selecting the excitation frequency. Figure 3. Relationship Between Excitation Frequency and Sensitivity of Differential Transformer Ⅴ The Cause of the ErrorThe error refers to the deviation between the actual and ideal characteristics of the sensor. Here, the system error inherent in the sensor itself and random error is mainly analyzed, and the error in the measurement method is not involved.• Influence of amplitude and frequency of excitation power supplyFluctuations in the magnitude of the excitation supply voltage cause changes in the strength of the excitation field of the coil to directly affect the output potential. The frequency fluctuations have little effect.• The effect of temperature changesChanges in ambient temperature cause changes in the magnetic permeability of the coil and the magnet, causing a change in the magnetic field of the coil to cause temperature drift. This effect is more severe when the coil quality factor is low. The use of constant current source excitation is more advantageous than the constant voltage source. Properly increasing the quality factor of the coil and using a differential bridge can reduce the effects of temperature.• Zero residual voltageWhen the armature of the differential transformer is in the neutral position, the ideal output voltage should be zero. But in fact, when using a bridge circuit, there is always a small voltage value (from a few millivolts to tens of millivolts) at zero point, which is called the zero residual voltage. Figure 4 is an enlarged output characteristic of the zero residual voltage. The dotted line is the ideal characteristic and the solid line indicates the actual characteristics. The presence of a zero residual voltage causes an insensitive zone near the zero point. Figure 4. Zero Residual Voltage of the Differential TransformerThe waveform of the zero residual voltage is very complicated and irregular. It is analyzed to include the fundamental wave in-phase component, the fundamental wave orthogonal component, and the second and third harmonics as well as the electromagnetic interference waves with small amplitude. The reasons why the zero residual voltage is generated are as follows:• Fundamental wave component: Since the winding of the two secondary windings of the differential transformer can not be completely identical in process, its equivalent circuit parameters (mutual inductance, self-inductance and loss resistance, etc.) cannot be completely equal, thus two induced potential values are not equal. The copper loss resistance of the primary coil, the iron loss and material non-uniformity of the magnetically permeable material and the presence of the inter-turn coil capacitance cause the excitation current to be out of phase with the generated magnetic flux.The above factors cause the induced potentials in the two secondary coils to be not only unequal in value but also in phase. The zero residual voltage generated by the difference in phase cannot be eliminated by adjusting the armature displacement. • High-order harmonics: The high-order harmonics are mainly caused by the nonlinearity of the magnetization curve of the magnetically permeable material. Due to the effects of hysteresis loss and magnetic saturation, the excitation current is inconsistent with the magnetic flux waveform, resulting in a non-sinusoidal wave (mainly the third harmonic flux), thereby inducing a non-sinusoidal potential in the secondary winding. The general method for eliminating zero residual voltage:— From the design and process, try to ensure the symmetry of the coil and the magnetic circuit. The structure can adopt the magnetic circuit adjustment mechanism; when selecting the working point of the magnetic circuit, it should be ensured that the magnetic field does not work in the saturation region of the magnetization curve.— Use the appropriate measurement line. The phase-sensitive detection circuit can not only identify the moving direction of the armature but also eliminate the high-order harmonic zero residual voltage of the armature in the middle position. As shown in figure 5, after using the phase-sensitive detection, the characteristic curve of the armature reverse stroke changes from 1 to 2, thereby eliminating the zero residual voltage. Figure 5. Output Characteristics After Phase-sensitive Detection— Use compensation lines. In applications of a differential transformer, there are many circuit types used to eliminate the zero residual voltage, which can be summarized as follows:▲Add series resistors to eliminate the in-phase component of the fundamental wave; generally the resistance of the series resistor is very small such as 0.5~5Ω, and is wound with constant wire.▲Add parallel resistors to eliminate the fundamental wave orthogonal component, but it has an effect on the in-phase component of the fundamental wave; the resistance of the shunt resistor is from tens to hundreds of kiloohms.▲Shunt capacitor, change phase shift, and compensate for high-order harmonics; parallel capacitor value is in the range of 100 ~ 500pf.▲Add feedback winding and feedback capacitor to compensate for fundamental wave and high-order harmonics.In fact, these values are determined experimentally; based on the working principle of the differential transformer and the cause of the zero residual voltage, the above methods can be modified and combined, and it is also possible to design a new compensation circuit. Figure 6 shows some line schematics for compensating for zero residual voltage for reference. Figure 6. Zero Residual Voltage Compensation Circuit of Differential Transformer Ⅵ The Measurement Circuit6.1 Differential DC output circuitThe output voltage of the differential transformer is an AC signal whose amplitude is proportional to the armature displacement. If the output value is measured with an AC voltmeter, it can only reflect the magnitude of the armature displacement and cannot reflect the direction of the displacement. Secondly, there is a certain zero residual voltage in the AC voltage output. Even with various compensation methods, it can only be reduced and cannot be completely eliminated. Therefore, the DC output circuit is commonly used in engineering practice, which can reflect the displacement direction of the armature and compensate for the zero residual voltage. The DC output circuit has two forms: one is a differential phase-sensitive detector circuit, and the other is a differential rectifier circuit.The differential rectifier circuit is shown in Figure 7. This circuit is relatively simple. It does not need to compare the voltage windings. It does not need to consider the influences if the phase adjustment and the zero residual voltage. The influence on the sensing and distributed capacitance can also be ignored. In addition, since the rectifying portion is on the differential output side, the two DC conveying lines are convenient to connect, and can be transported at a long distance, and are widely used. Figure 7. Differential Rectifier Circuita) full-wave current output         b) half-wave current outputc) full-wave voltage output         d) half-wave voltage outputDifferential phase sensitive detector circuits come in many forms. Figure 8 shows two examples, one is a full wave circuit and the other is a half-wave circuit. The phase sensitive detector circuit requires that the comparison voltage and the secondary transformer output voltage of the differential transformer have the same frequency and the same phase or opposite phase.  To ensure this, a phase-shifting circuit is usually connected to the circuit. In addition, it is required that the comparison voltage amplitude should be as large as possible (because the comparison voltage acts as a switch in the detector circuit, and if it is less than the signal voltage, the switch cannot be turned on), generally it should be 3 to 5 times the signal voltage. In the figure, Rw is the bridge zero potentiometer. For the case of measuring small displacements, since the output signal is small, the input amplifier is also connected to the circuit. Figure 8. Differential Phase-sensitive Detection Circuita) full-wave detection         b) half-wave detection6.2 DC differential transformer circuitThe working principle of the DC differential transformer is exactly the same as that of the ordinary differential transformer described above. The only difference is that the power supply used in the instrument is a DC power supply (dry battery, battery, etc.). The schematic diagram of the DC differential transformer is shown in figure 9. It consists of a DC power supply, a multivibrator, a differential rectifier circuit, a filter and so on. Figure 9. Schematic Diagram of DC Differential Transformer CircuitThe multivibrator provides a high frequency excitation power supply for the differential transformer, which can be a square wave, a triangular wave or a sine wave. DC differential transformers are commonly used in the following applications:◆ The measuring point is far from the control room (more than 100m);◆ Simultaneous use of multiple differential transformers and requires no interference with each other and with other equipment;◆ Where explosion protection is required;◆ Requires easy to carry, such as working in the field. Ⅶ The Application of Differential TransformerDisplacement measurement is the most important use of differential transformers. Any physical quantity that can be transformed into a displacement can be measured with a differential transformer. It is noted that the differential transformer measurement is generally contact type. In some cases, it will affect the state of the measured object (such as vibration), which is the so-called “load effect”. In this case, other types of sensors must be used such as eddy current sensors, etc.◆ It can be used as the main component of many precision measuring instruments, such as making high-precision inductance comparator with corresponding measuring devices, which can perform various precise measurements on parts: length, inner diameter, outer diameter, non-parallelism, non-flatness, non-perpendicularity, vibration, eccentricity, and ellipticity.◆ As the main measuring part of the bearing rolling element automatic sorting machine, it can sort large and small steel balls, large and small cylinders, large and small round vertebrae, needle roller and so on.◆ It is used to measure the expansion, elongation, strain, movement, etc. of various parts. With a variety of sensors, its displacement measurement range can be from ±3μm to over 1000mm.◆ Vibration and acceleration measurements. An accelerometer for measuring vibration can be constructed by using a differential transformer and a cantilever beam elastic support.◆ Pressure measurement. The differential transformer and the elastic sensitive component (diaphragm, bellows, spring tube, etc.) can be combined to form a pressure sensor of the open-loop system and a force-balanced pressure gauge of the closed-loop system. Due to the excellent characteristic of differential transformer as the displacement sensor, it has been applied in almost all industrial fields and several specific examples are described below.• Steel industry: blast furnace top-level detection, continuous casting roll gap, sand type vibration, convexity detection, position detection of sliding water nozzles such as ladle and tundish.• Heavy motor industry: the main valve of the steam turbine, the valve lift detection of the bypass valve, and the posture monitoring of the elevator.• Construction machinery industry: Measuring head for numerical control machine tool simulation test.• Ceramic industry: thermal expansion testing of refractory materials, shape detection of templating glass.• Ship and vehicle industry: fuel classification position detection of diesel engine, dynamic characteristic detection of fuel injection valve of an automobile engine, and eccentricity detection of tire and wheel.• Weighing machine industry: a device that automatically measures the weight of the bag, and a weighting machine for the asphalt carrying device.• Measuring instrument, testing machine industry: used for traction test, creep test of metal materials and plastics, signal conversion part of flow meter and liquid level meter, a mechanical test of civil building components.• General industry: spacer separators for assembling bearings, motion deviation detection during stamping, and measurement of workpiece size and shape deviation. Ⅷ Application Circuit Examples of Differential Transformer8.1 MZK-4R Grinding Machine Automatic Control DeviceThis device is used on automatic or semi-automatic grinding machines. During the grinding process of the workpiece, the control device can accurately output 4 signals according to the amount of the pre-regulation to control the introduction of the grinding head, rough grinding, fine grinding, light grinding and exit, etc., thus realizing the automatic measurement and control of the grinding process. • Working process of the grinding machineWhen the workpiece is loaded, the measuring device first enters the workpiece for measurement. If the workpiece size meets the pre-adjusted result, the control device sends a “starting” signal, the grinding head enters the workpiece and moves forward quickly to the machining direction, and coarse grinding starts. Taking the internal grinding as an example, as the workpiece size of the grinding wheel becomes smaller, the output signal of the measuring head also becomes smaller.  When the preset position is reached, the trigger sequentially sends three signals, that is, the “rough grinding end” signal, indicating that the rough grinding is finished, so that the moving speed of the grinding wheel is reduced, and the fine grinding starts; when the fine grinding is finished, the “finishing end” signal is issued, so that the grinding wheel stops moving and the light grinding starts; when the preset size is reached, the “light grinding end” signal is issued to make the grinding wheel and the detection device exit quickly. • Working principle of measuring head (sensor)The measuring head adopts a differential transformer type displacement sensor, and its structure is as shown in figure 10(a). The iron core moves to the right, so that the induced potential of the winding A decreases, and the induced potential of the winding B increases (and vice versa). The two windings and the resistors R1 and R2 in the measuring device form a bridge to realize differential output, as shown in figure 10(b). Figure 10. Schematic Diagram of the Differential TransformerThe primary coil is excited by a square wave generator with a square wave frequency of 3 kHz and an effective voltage value of 3.5V. Along with the change of the displacement of the core, a corresponding voltage variable is generated between the boom of the potentiometer Rw and the secondary common tap (ground) of the measuring head. The displacement-voltage characteristic curve in figure 11 is obtained after the voltage variable is amplified and phase-sensitive rectified. Figure 11. Output Characteristic Curve of Differential TransformerIn the figure, the S-T segment is the full linear range, wherein the H-E segment (high precision) is the ×1 gear indication range, and the K-C segment (low precision) is the ×10 gear indication range. The“start”signal 0 is sent in the D-A segment, the“rough grinding end” signal 1 is sent in the G-B segment, and the“fine grinding end” signal is 2 sent in the 0-F segment. The“light grinding end”signal 3 is sent at point 0. • Principle of the circuit①The circuit block diagram shown in figure 12. Figure 12. Circuit Block Diagram of Control Device②Explanation of the circuit principleThe device consists of six parts: ▲Input bridge, the two arms are composed of two secondary windings of the measuring head, the other two arms are composed of R84 and R85, the potentiometer VR1 is used for the electrical zero points coarse adjustment, the VR2 is used for the zero points fine adjustment, and the R86 is used to limit the zero point adjustment range.In order to obtain the reference voltage for amplifier calibration, a voltage is obtained by the square wave generator, and another bridge is formed by transformers TR4, R88, and R89, and VR4 is used to adjust the reference voltage. ▲The amplifier amplifies the weak signal obtained in the input circuit to have sufficient amplitude to complete the measurement and control. T15, T17, and T18 form a voltage amplifier with gains of about 10, 20, and 20 dB, respectively. T16 is a buffer stage. T19 and T20 form a push-pull power amplifier stage, and the voltage gain of the amplifier is about 60 to 70 dB. In order to achieve higher stability and linearity, deeper negative feedback is added to each stage. The negative feedback of first stage is adjustable, and the total gain of the amplifier is adjusted by VR3. ▲Phase-sensitive rectification and indicating circuit are used to complete the rectification and identify the phase of the input signal. The half-wave rectification circuit is composed of D15 and D16, and the blocking voltage is 13V, which is provided by the square wave generator.The rectified DC ramp signal is used as an input to the trigger on the one hand and as a panel indicator on the other. The μ meter is a microampere meter with a full-scale of 150μA, and full-scale indications of 50μ and 500μ are obtained with shunt resistors R90 and R91. D33 is used as a voltage clamp to protect the meter head. ▲Square wave generator, which is used to generate the excitation voltage required by the measuring head and the blocking voltage required for phase-sensitive rectification. The high rectangular coefficient multivibrator circuit is composed of T21 and T22, which is easy to start, high in frequency and amplitude stability, and its oscillation frequency is 3 to 3.5 kHz. ▲Trigger, according to the comparison of the output voltage of the phase-sensitive rectification and the pre-adjustment voltage, four different control signal outputs are sequentially generated. The circuit adopts a trigger with an emitter coupled by a Zener tube, which has a small temperature drift and convenient backlash adjustment. Among them, VR5, VR6, VR7, and VR8 are used as the adjustment potentiometers for the four signals of “0”, “1”, “2”, and “3” on the panel. ▲Power:-24V, used for power relay after rectification and filtering;-15V, generated by the series regulator circuit and is used as the collector voltage of each transistor and the trigger pre-call;+6V, generated by the shunt regulator circuit and is supplied for the bias and pre-call of the trigger. • Main technical indicators✿ Instrument indexing and error:High precision (G) 1μ/division; full scale -10～+50μ; error ≤1.5μLow precision (D) 20μ/division; full scale -100～+500μ; error ≤30μ✿ Adjustable range of control signal :Signal "0", 350～500μ;Signal "1", 30～100μ;Signal "2", 0 ~ 30μ;Signal "3", -10 ~ +10μ✿ Electrical zero adjustable range:Not less than 100μ, and ±5μ fine adjustment✿ Repeat error:No more than 1μ✿ (Grid) voltage adjustment error:No more than 3μ✿ Instability:Time drift is no more than 10μ/4 hours; temperature drift is no more than 10μ/ 10℃ 8.2 ZD41B Short Cylindrical Roller Sorting MachineThis machine is composed of high-precision micrometer (differential transformer), combined with transistor circuit to form measurement and logic control device to complete the task of automatically sorting short cylindrical bearing rollers. • Main technical indicators◆ Measurement range:length is no more than 15mm5 to 15 mm in diameter◆ Accuracy:1μ, 2μ, 3μIf the magnification and radial grouping potentiometer are re-tuned, any grouping in the range of 0.5 to 5μ can be obtained.◆ Number of groups:10 groups.◆ Speed:28/min to 65/min,can be adjusted arbitrarily • Working principleThe measurement and classification of the radial dimensions of the roller are automated. The roller to be tested is manually placed in a disc-shaped hopper, passed through the vibrating roller to the feeding position along the pipe, and then pushed into the measuring portion by the reciprocating push rod for radial measurement. When different sizes of rollers enter the measurement site for measurement, the differential transformer guide core is displaced in the coil, so that the differential transformer outputs an alternating current signal proportional to the change in the size of the roller, and tiny electrical signal is amplified, rectified, and then amplified by the DC amplifier, so that the corresponding trigger drives the relay and the electromagnet to open the storage valve of the sorting group, so that the measured rollers of different diameters are placed in different sorting bins for automated measurement and sorting. Here we mainly introduce the radial dimension measurement part, namely the differential transformer and its secondary circuit. The measuring part of the roller consists of a differential transformer, a 4KHz oscillator, an attenuator, a low-frequency AC amplifier, a phase-sensitive rectification, a DC amplifier, a regulated power supply, etc. ① Micrometer (differential transformer): The differential transformer is used to convert the diameter of the roller into a change in the amount of electricity. The primary coil is excited by a rectangular wave with a frequency of 4 kHz and an amplitude of 2 to 3 volts. Thus, the voltages of u2 and u3 are induced in the secondary coil. The different names of the secondary coils are connected as a common point ground, and the other ends serve as a differential output and form a bridge balance loop with the resistors R1, R2 and the potentiometer VR.  When the iron core is at the center position of the two secondary coils, since the magnetic resistance of the two coils is equal, the bridge is in a balanced state, and the differential transformer output E2=0 (u2=u3). In a static state, due to the self-weight of the iron core and the guide rod, the iron core is located at the lowermost end of the secondary coil, thus outputting a negative polarity voltage; when the roller is measured, the guide rod is displaced upward, and the iron core is also displaced upward in the differential coil. The output voltage varies with the displacement. When the displacement exceeds the center position, the differential transformer outputs a positive voltage. ② Oscillator: A high-frequency triode is used as a capacitive voltage divider oscillator with an oscillation frequency of 4KHz. This circuit feature avoids the difficulty of inductive oscillator winding. The intermediate transformer is used to couple the output, and then through the first-stage voltage amplification, the two pairs of Zener diodes are used to limit the clipping to form a rectangular wave with constant amplitude (2~3V), one way is for the primary excitation of the differential transformer and the other is for the phase-sensitive rectification comparison voltage. ③ AC amplifier: three-stage amplification circuit and transformer-coupled output. In order to keep the amplifier gain stable, 20dB negative feedback is introduced between the first and second stage, and the total gain is 75~80dB. ④ Phase-sensitive rectifier circuit: diode half-wave phase-sensitive rectification is used, the comparison voltage amplitude is high, and both diodes are turned on in the positive half cycle. The signal voltage is small, the positive voltage is output in the same phase with the comparison voltage, and the negative voltage is output in the opposite phase with the comparison voltage. ⑤ DC differential amplifier: The DC voltage output from the phase-sensitive rectifier circuit is further amplified and the polarity is converted. When inputting ±50mV, the differential output is 4~12V. 8.3 Discussion of Differential Transformer Application(1) The above example uses the two directions of the differential transformer and is determined for the special purpose of roller sorting. When measuring with a roller of nominal size, the differential transformer core is just adjusted to the center position, the positive tolerance roller produces a positive displacement, and the positive voltage is output; the negative tolerance roller produces a negative displacement and outputs a negative voltage. This makes full use of the linear range of the differential transformer. For different applications, especially for small-range, high-precision measurements, there is no need to distinguish the direction of the displacement. It is also possible to use only the displacement of the differential transformer in one direction, and the corresponding circuit can be simplified. (2) This product was a product of the 1970s, so a transistor discrete component circuit was used. Today's electronic technology and the component levels are no longer the same. AC amplifiers and DC amplifiers can be used with operational amplifiers, and performance is much better than discrete component circuits. The basic principles of the circuit and the various functional parts are still applicable and can be designed accordingly. (3) Nowadays, the application of single-chip microcomputers can completely replace the various logic circuits in the past. In the case of a single-chip microcomputer, the entire circuit design may vary greatly. For example, the oscillation source can be digitized (crystal oscillator frequency division may be directly generated by a single-chip microcomputer), and the measurement result is digitized (via A/D conversion), and a large number of analog comparators, triggers can be replaced by program judgment methods.  Furthermore, with the precise timing and synchronization function of the single-chip microcomputer, A/D conversion can be directly performed on the AC signal sampling, and the phase-sensitive rectifier circuit can be omitted. After the measurement results are digitized, data transmission can be used instead of analog transmission, thus precision will not be lost, interference will not exist and transmission distance will be long. Ⅸ FAQ1. Why does LVDT use high voltage?It is a type of electrical transformer used for measuring linear displacement.The linear variable differential transformer has three solenoidal coils placed end-to-end around a tube. The center coil is the primary, and the two outer coils are the top and bottom secondaries. A cylindrical ferromagnetic core, attached to the object whose position is to be measured, slides along the axis of the tube. An AC current drives the primary and causes a voltage to be induced in each secondary proportional to the length of the core linking to the secondary.Cutaway view of an LVDT. Current is driven through the primary coil at A, causing an induction current to be generated through the secondary coils at B. When the core is displaced toward the top, the voltage in the top secondary coil increases as the voltage in the bottom decreases. The resulting output voltage increases from zero. This voltage is in phase with the primary voltage. When the core moves in the other direction, the output voltage also increases from zero, but its phase is opposite to that of the primary. The phase of the output voltage determines the direction of the displacement (up or down) and amplitude indicates the amount of displacement.  2. What are the advantages of using an LVDT?• Very reliable: Long sensor lifespan due to near frictionless operation of most models.• Very high resolution: Because of the near-frictionless movement they provide virtually infinite resolution. Even the smallest changes can be detected.• Damage resistant: In some models, both ends of the tube are open, preventing sensor damage if the test article pushes the rod farther than expected (except for collision with the tube itself).• Null point stability: The zero or null point of the sensor is extremely repeatable due to the construction of the sensor itself.• Wide range of operating temperatures: There are LVDT models available that can withstand cryogenic temperatures (-200℃/ -328℉) as well as high temperatures (650℃/ 1200℉)• Low hysteresis/ high positional accuracy and repeatability• Absolute reading output device: As opposed to an incremental output device, the reading from an LVDT will be the same before and after its power is cycled (assuming that the object under test did not move).  3.What are the disadvantages of using an LVDT?• Limited measurement distance: Even the largest LVDTs are limited to less than 1m (~27'') measurement ranges.• Can be affected by magnetic fields (models with shielding are common as a result).• AC models require a precise AC excitation from an LVDT signal conditioner.• DC LVDT models have an inferior shock, vibration and temperature specifications compared to AC LVDT models. 4. How do I interface an LVDT output with PLC?The output is voltage so you will need an analog input card which can take in a voltage input and then inside the PLC you will scale what that voltage corresponds to. For eg 10 V could mean 10 mm or 10 degrees etc. If the output is current them you would need an analog IP card which accepts current. Most common current used is 4–20 mA. 5. What are the applications of the Bourdon tube and the LVDT method for pressure measurement?A bourdon tube is a curved, hollow, closed end tube which can be pressurized. The pressure will attempt to straighten out the tube as it is increased. The amount of movement is typically very small but can be mechanically amplified. The translation of the end of the tube can be a linear indication of the pressure applied to the other end.Pressure gauges have used this technique for over a century and a half to indicate pressure manually on a dial gauge with a linkage that moves a dial pointer.To make electronic readouts of pressure to remote dials or to computers, a linear movement to electrical voltage is needed. An LVDT satisfies this need. An LVDT is a variable transformer consisting of a movable magnetic core sliding inside a tube with a primary and secondary winding. As the core is displaced the coupling between windings is varied linearly. If a small AC voltage is applied to the primary then the amplitude of the secondary output can be measuered in amplitude to indicate proportional to the pressure.So this makes a hybrid sensor or transducer, pressure to displacement connected to a displacement to variable voltage resulting in a pressure to variable voltage device.Technically this is an older way of converting pressure to volts… and is subject to hysteresis or mechanical backlash. Most modern P-V transducers use strain gauge bridge followed by an instrumentation amplifier to have fewer moving parts and less hysteresis. 6. Discuss various applications where LVDT’s can be used?They can be used in any application where a highly accurate measurement of linear displacement or position is needed. This includes precision gaging systems for measurement and metrology, feedback transducers for precision servomechanisms, torque, force and moment transducers, materials testing equipment (tensile testers, rheometers, fatigue testers, etc.). 7.What is the accuracy of a LVDT and an inductance transducer in a displacement measurement?Accuracy for both devices depends on the way they are designed, made and used, and the materials from which they are made. As well as calibration.However, neither on their own give “readings”. They need conditioning and interface circuitry. (I do recognise that the “inductance transducer” is a two-word item, and that the second word - transducer - implys that at least some form of signal conditioning exists therein.)That cicuitry is at least as important as the device itself.To give typical values for accuracy, is difficult without more specifics, though it is usual to be able to achieve several significant figures of accuracy out of each. 8. What is LVDT in measurement?A Linear Variable Differential Transducer is a sensor based on the idea of transformers. As its name shows it's a Linear sensor used in measuring displacements.  It has an iron core that moves up and down in the gap separating the primary and secondary coils. So the coils are not physically connected. The secondary coils are connected in opposition such that the output voltage is the difference between the voltages induced in the first and second secondary coils. The components whose Displacement is required to be measured should be connected to the core, so the input to the sensor is the displacement، the output would be the differential voltage output and after some manipulation using the sensitivity and sensor resolution, the displacement can be obtained. 9. How does a DC LVDT work?An oscillator/demodulator circuit built into the displacement transducer supplies the excitation and converts the return signal to a dc voltage. ... As the transducer contains internal signal conditioning electronics, there is no need for external signal conditioning. 10. Is LVDT an active transducer?The active transducer is also called a self-generating type transducer. ... Example of an active transducer is the bourdon tube. An example of a passive transducer is LVDT (linear variable differential transformer). It generates electric current or voltage directly in response to environmental stimulation.

IntroductionIn electronics, current sense amplifiers are special-purpose amplifiers that output a voltage proportional to the current flowing in a power rail. They are often referred to as current shunt amplifiers because they use a shunt resistor in the power rail that provides a small voltage drop when current flows through the resistor. These devices are designed to handle common-mode voltages that can exceed their own supply voltage. The working principle of a current sensing amplifier is based on Ohm's law (V = I × R), where the voltage drop across the sense resistor is converted and amplified to a measurable output voltage by the current sense amplifier.Ⅰ Current Sense Amplifier Overview1.1 What is a Current Sense Amplifier?Current sense amplifiers are designed for the specific purpose of amplifying very small sensed voltages across a shunt resistor, typically within a range of 10 to 100 mV. These amplifiers are optimized for DC precision (e.g., low input offset voltage, typically less than 50 µV) and high common-mode rejection ratio (CMRR). Current sensing amplifiers can measure current flowing in a single direction (unidirectional) or in both directions through the sensing resistor. When an amplifier is capable of detecting current flow in both directions, it is called a bidirectional current sensing amplifier. Modern current sense amplifiers also feature enhanced bandwidth (up to several MHz), low quiescent current (as low as 50 µA), and integrated protection features such as overcurrent detection and alert outputs.1.2 Common-Mode Voltage and CMRRCommon-mode voltage is critical for both standard amplifiers and current sense amplifiers. The common-mode voltage refers to the average voltage applied to the inputs of the amplifier. This parameter is crucial because the amplifier has a limited ability to distinguish and differentiate signals depending on the common-mode voltage level. A standard op-amp's input range is typically insufficient for precision current sensing operations. In current sense amplifiers, the common-mode voltage range often extends well beyond the actual supply voltage of the amplifier. For example, modern current sense amplifiers can achieve supply operating voltage ranges from -4 V to +80 V, with some specialized devices supporting ranges up to +120 V or even higher for automotive and industrial applications.Op-Amp CMRR (Common Mode Rejection Ratio) ExplainedThe CMRR (common-mode rejection ratio) is the ratio of differential gain to common-mode gain, typically expressed in decibels (dB). For an ideal op-amp, the CMRR is infinite, but in real circuits, it typically ranges from 80 to 120 dB for high-performance current sense amplifiers. A high CMRR means that the amplifier can effectively reject common-mode signals while accurately amplifying the differential signal. For a current sense amplifier, high CMRR is essential because it determines how well the amplifier can measure small differential voltages in the presence of large common-mode voltages. Modern current sense amplifiers achieve CMRR values exceeding 100 dB, enabling them to sense tiny voltage drops across shunt resistors even when the common-mode voltage is several orders of magnitude larger. The high CMRR also helps eliminate noise on the current sense lines, improving measurement accuracy and system reliability.1.3 Main Types of Current Sense AmplifiersHigh-side AmplifiersThe current is measured between the supply rail and the load. The DC voltage applied to the input pins can be much higher than the amplifier's power supply voltage. High-side sensing is preferred in applications requiring ground fault detection and load diagnostics.Low-side AmplifiersThe current is measured between the load and ground. The voltage applied to the input pins is close to ground potential. Low-side sensing is simpler to implement but can interfere with ground reference integrity.Bidirectional AmplifiersThese amplifiers can measure current flow in both directions, making them ideal for battery monitoring, motor control, and applications with regenerative braking.Integrated Current Sense Amplifiers with ADCModern devices integrate analog-to-digital converters (ADC) and digital interfaces (I²C, SPI) for direct microcontroller communication, simplifying system design.Figure 1. High-side Current Sensing AmplifierⅡ Current Sense Amplifiers vs Common AmplifiersCurrent sense amplifiers and common operational amplifiers have different specifications and are designed for specific purposes. Standard operational amplifiers typically cannot amplify very small differential voltages in the presence of large common-mode voltages and have relatively low CMRR (typically 80-90 dB). In contrast, precision current sense amplifiers can detect and amplify very small voltage drops (as low as a few millivolts) while maintaining high CMRR (100-120 dB or higher).For normal operational amplifiers, the input voltage must remain between the power supply rails (VCC and VEE), and the amplifiers can only operate on input signals within this range. In a standard amplifier, applying an external voltage beyond the power rails to the input pins will activate internal ESD protection diodes, potentially causing large currents to flow and damaging the device.However, current sense amplifiers are designed to handle input voltages that far exceed their supply voltage. For example, an amplifier powered by 3.3V or 5V can safely measure voltages on power rails operating at 12V, 24V, 48V, or even higher. These amplifiers use specialized input architectures and protection circuits that allow them to operate with high common-mode voltages. When the common-mode input voltage exceeds VCC, the amplifier employs advanced circuit techniques to maintain accurate measurements without damage. Some modern current sense amplifiers also feature integrated overcurrent detection, alert outputs, and enhanced EMI/RFI rejection for robust performance in noisy industrial and automotive environments. Ⅲ How to Design a Circuit Using Current Sense AmplifiersConsider a design example with a 12V, 1A power rail where high-precision current sensing is required. Current sense amplifiers provide an ideal solution for this application. However, proper component selection is critical for optimal performance.For this application, select a current sense amplifier rated for at least 12V common-mode voltage with sufficient bandwidth for the application (typically 100 kHz to 1 MHz for DC and low-frequency AC measurements). Choose between high-side and low-side sensing based on system requirements. High-side current sensing is preferred for detecting fault or short-circuit conditions while maintaining ground integrity. Low-side current sensing offers simpler implementation but disrupts the ground reference path.The LT6108 (now part of Analog Devices) is an excellent choice for this application. This amplifier features a wide input common-mode voltage range (-0.3V to +60V), high gain accuracy, and low offset voltage. The device can operate with supply voltages from 2.9V to 60V, making it suitable for both 12V and lower voltage control circuits. Key specifications include: input offset voltage of 50 µV (typical), CMRR of 125 dB (minimum), and bandwidth of 500 kHz.Figure 2. LT6108 Circuit for Fault Protection with Fast Latching Load DisconnectThe circuit above demonstrates a practical implementation using the LT6108. A 1-ohm sense resistor creates a voltage drop proportional to the load current (1V drop at 1A). The IRF9640 P-channel MOSFET serves as the switching element, while the 2N2222 NPN transistor (note: 2N2700 in the original text appears to be a typo) provides the control function. The amplifier output can trigger the switching MOSFET to disconnect the load when current exceeds a preset threshold. In this configuration, the trip point is set at 250 mA. The circuit will open when current exceeds this limit, providing overcurrent protection. For different current thresholds (e.g., 1A), adjust the voltage divider network at the comparator input. The VOUT pin provides a voltage proportional to the sensed current, enabling real-time current monitoring. This circuit topology can be adapted using other current sense amplifiers with appropriate input voltage ranges. For higher voltage applications (24V, 48V), select amplifiers with extended common-mode voltage ranges, such as the INA240 (up to 80V) or MAX40080 (up to 60V).Design Considerations:Sense Resistor Selection: Choose a value that provides adequate voltage drop (typically 50-100 mV at full scale) while minimizing power dissipation. For 1A measurement, resistor values between 0.05Ω and 0.1Ω are common.PCB Layout: Use Kelvin connections to the sense resistor to eliminate errors from trace resistance. Keep traces short and symmetric to minimize offset errors.Filtering: Add input filtering capacitors (typically 0.1 µF ceramic) close to the amplifier inputs to reduce noise and improve stability.Gain Setting: Many current sense amplifiers offer programmable gain through external resistors, allowing optimization for specific current ranges. Ⅳ Common Applications of Current Sensing ICs4.1 Low-side Current Sense ICLow-side current sensing places the shunt resistor between the load and ground. This configuration measures current by monitoring the voltage drop across the sense resistor in the ground return path. The diagrams below demonstrate low-side measurement circuits.Practical implementations include using the INA181 current sense amplifier with its output connected to an ADC (Analog-to-Digital Converter) for digital processing. Another approach employs the AD8202 current sense amplifier from Analog Devices for sensing current through inductive loads. Modern alternatives include the INA190 series and MAX9938, which offer enhanced precision and lower power consumption.1) AdvantagesLow-side current measurement offers several benefits. The configuration is straightforward to implement because the common-mode voltage remains close to ground potential. Standard operational amplifiers or simple differential amplifiers can be used since high common-mode rejection is not critical. The low common-mode voltage simplifies circuit design and reduces component costs. Additionally, low-side sensing typically provides better noise immunity in the measurement path.2) DisadvantagesThe primary limitation of low-side current measurement is the disruption of the ground reference. Placing the shunt resistor in series with the ground path means the load no longer has a direct connection to system ground. This can cause ground bounce issues, interfere with proper operation of the load, and make it impossible to detect ground faults or short circuits to ground. Additionally, low-side sensing cannot detect leakage currents or faults that bypass the sense resistor. For these reasons, high-side sensing is often preferred in safety-critical applications.4.2 High-side Current Sense ICUnlike low-side current sensing, high-side current sensing places the shunt resistor between the positive power supply and the load. This configuration preserves ground integrity while enabling current measurement. The circuits shown below illustrate high-side current sensing implementations.Practical examples include the TI INA240, which provides analog output or integrated comparators for overcurrent detection. Some variants offer digital output via I²C interface for direct microcontroller communication. The Linear Technology LT6100 (now Analog Devices) demonstrates high-side current sensing with a fused load for enhanced protection. Modern alternatives include the INA226 (with integrated 16-bit ADC and I²C interface), MAX40080 (with integrated 12-bit ADC), and INA3221 (triple-channel monitor for multi-rail systems).Figure 3. TI INA240 in Circuit1) AdvantagesHigh-side current measurement offers significant advantages over low-side sensing. First, it maintains ground integrity, ensuring the load has a solid ground reference. This prevents ground bounce and interference issues. Second, it enables detection of all fault conditions, including short circuits to ground, since all current must flow through the sense resistor. Third, high-side sensing allows accurate measurement of the actual load current without ground path interference. Fourth, it provides better system diagnostics and fault isolation capabilities. Finally, high-side sensing is essential for battery monitoring applications where the negative terminal is grounded.2) DisadvantagesThe primary challenge of high-side current sensing is the requirement for high common-mode rejection. The small differential voltage (typically 50-100 mV) across the shunt resistor sits on top of a large common-mode voltage equal to the supply rail voltage. This requires specialized amplifiers with high CMRR (>100 dB) and wide common-mode input ranges. Additionally, high-side sensing circuits are typically more complex and expensive than low-side alternatives. However, advances in integrated circuit technology have made high-side current sense amplifiers increasingly affordable and easy to implement.4.3 Bidirectional Current Sense ICBidirectional current sense circuits use a single shunt resistor but require amplifiers capable of detecting current flow in both directions. These circuits are essential for applications such as battery charge/discharge monitoring, motor control with regenerative braking, and power management systems with bidirectional power flow.Several architectures enable bidirectional current sensing. One approach uses two current sense amplifiers (such as the INA300) connected in a configuration where each amplifier detects current flow in one direction. The circuit requires reverse polarity protection and switching logic to select the appropriate amplifier output based on current direction.A more elegant solution uses integrated bidirectional current sense amplifiers such as the INA240, INA180, or MAX40080. These devices use a reference voltage (typically mid-supply or an external reference) as the zero-current point. When current flows in one direction, the output voltage rises above the reference; when current reverses, the output falls below the reference. The differential output voltage is proportional to current magnitude, while the polarity indicates current direction.Modern bidirectional amplifiers like the INA226 and INA3221 integrate ADCs and digital interfaces, providing signed current measurements directly to microcontrollers. These devices simplify system design by eliminating external ADCs and reference voltage circuits. For high-precision applications, devices like the MAX40080 offer 12-bit resolution with ±0.1% accuracy across the full bidirectional range.4.4 Isolated Current Sense ICIsolated current sensing techniques provide galvanic isolation between the current measurement circuit and the control electronics. This is essential for high-voltage applications, safety-critical systems, and situations requiring ground loop elimination. Several isolation methods are available:Current Transformer (CT) Isolation: Uses magnetic coupling through a transformer core. The primary winding carries the measured current, inducing a proportional voltage in the secondary winding. This method is limited to AC current measurement and provides excellent isolation (typically >4 kV).Hall Effect Sensors: Measure the magnetic field generated by current flow through a conductor. Hall effect sensors can measure both DC and AC currents and provide good isolation. Examples include the ACS712, ACS724, and TMCS1100 series.Isolated Amplifiers: Use capacitive or magnetic isolation to transmit the measurement signal across an isolation barrier. Examples include the AMC1200 (capacitive isolation), Si8920 (magnetic isolation), and ACPL-C87A (optical isolation). These devices typically provide 3-5 kV isolation and can measure both DC and AC currents.Rogowski Coils: Air-core coils that measure the rate of change of current (di/dt). These are ideal for high-frequency AC current measurement and provide inherent isolation.Isolated current sensing is mandatory in applications such as motor drives, solar inverters, electric vehicle charging systems, and industrial power monitoring where high voltages and safety requirements necessitate galvanic isolation between measurement and control circuits.Figure 4. Low-side Current Sensing CircuitⅤ Key Specifications and Selection CriteriaWhen selecting a current sense amplifier, consider the following critical specifications:Common-Mode Voltage Range: Must exceed the maximum voltage on the power rail being monitored. Include margin for transients and voltage spikes.Input Offset Voltage: Determines minimum detectable current. Lower offset voltage (typically <50 µV) enables accurate measurement of small currents.CMRR: Higher values (>100 dB) provide better rejection of common-mode noise and more accurate differential measurements.Bandwidth: Must be sufficient for the application. DC to 100 kHz for most power monitoring; 1 MHz or higher for motor control and fast transient detection.Gain Options: Fixed or programmable gain allows optimization for specific current ranges.Supply Voltage: Must be compatible with system power rails. Many devices operate from 2.7V to 5.5V for easy integration with digital systems.Quiescent Current: Important for battery-powered applications. Modern devices offer quiescent currents as low as 50 µA.Package and Size: SOT-23, SOIC, and DFN packages are common. Smaller packages reduce PCB footprint but may have thermal limitations.Integrated Features: Some devices include comparators, ADCs, digital interfaces (I²C, SPI), alert outputs, and overcurrent protection.Temperature Range and Accuracy: Industrial (-40°C to +125°C) and automotive (-40°C to +150°C) grades are available. Temperature drift should be <2 µV/°C for precision applications.Ⅵ Emerging Trends and Future DevelopmentsThe current sense amplifier market continues to evolve with several notable trends:Higher Integration: Modern devices integrate ADCs, digital interfaces, voltage monitors, and power calculation engines on a single chip, reducing component count and system cost.Wider Voltage Ranges: New amplifiers support common-mode voltages up to 120V or higher, enabling direct monitoring of high-voltage rails without external attenuation.Lower Power Consumption: Shutdown modes and ultra-low quiescent current (<50 µA) enable use in battery-powered IoT devices and energy harvesting applications.Enhanced Accuracy: Improved manufacturing processes deliver offset voltages below 25 µV and gain errors below 0.1%, enabling precision measurements with smaller sense resistors and lower power loss.Automotive Qualification: AEC-Q100 qualified devices for electric vehicles, battery management systems, and 48V automotive systems.Digital Configurability: Software-programmable gain, filtering, and alert thresholds enable flexible, adaptive current monitoring systems.Multi-Channel Integration: Devices like the INA3221 integrate multiple current sense channels for simultaneous monitoring of multiple power rails.Ⅶ ConclusionAs an essential component of modern electronics, current sense amplifiers provide high-precision, flexible solutions for a wide array of applications including automotive systems, power management, battery monitoring, motor control, and industrial automation. Devices like the INA280, INA226, MAX40080, and LT6108 offer high-precision current measurement capabilities by accurately sensing voltage drops across shunt resistors. With diverse circuit requirements, a broad range of current sense amplifiers are available, including high-voltage, high-resolution, bidirectional, and isolated variants. The continued evolution of current sense amplifier technology—featuring higher integration, wider voltage ranges, lower power consumption, and enhanced digital connectivity—ensures these devices will remain critical components in next-generation power management and monitoring systems. When selecting a current sense amplifier, carefully consider application requirements including voltage range, accuracy, bandwidth, power consumption, and integration features to ensure optimal performance and system reliability. Frequently Asked Questions about Current Sense Amplifier Circuits1. What is a current sense amplifier?Current sense amplifiers (also called current shunt amplifiers) are special-purpose amplifiers that output a voltage proportional to the current flowing in a power rail. They utilize a "current-sense resistor" (shunt resistor) to convert the load current in the power rail to a small voltage, which is then amplified by the current sense amplifier. The currents in the power rail can range from milliamps to 20 A or more, requiring the current-sense resistor to be typically in the range of 1 mΩ to 100 mΩ. These amplifiers are specifically designed to handle high common-mode voltages while accurately measuring small differential voltages. 2. How does a current sense amplifier work?Current sense amplifiers work by measuring the small voltage drop across a shunt resistor placed in series with the load current. According to Ohm's law (V = I × R), the voltage drop is directly proportional to the current. The amplifier's differential inputs measure this voltage drop while rejecting the large common-mode voltage present on the power rail. The amplifier then amplifies the differential signal to produce an output voltage that can be easily measured by ADCs or comparators. Unlike normal differential amplifiers that are powered between two power supply rails (VCC and VEE) and can only handle signals between these rails, current sense amplifiers use specialized input stages that can tolerate input voltages far exceeding their supply voltage without activating ESD protection diodes or causing damage. 3. What are the main types of current sense amplifiers?The main types of current sense amplifiers include:High-Side Current Sense: Measures current between the power supply and load, maintaining ground integrity.Low-Side Current Sense: Measures current between the load and ground, offering simpler implementation.Bidirectional Current Sense: Measures current flow in both directions, essential for battery monitoring and regenerative systems.Isolated Current Sense: Provides galvanic isolation using magnetic, capacitive, or optical coupling for high-voltage and safety-critical applications. 4. What is the main purpose of a current sense amplifier?The main purpose of a current sense amplifier is to accurately measure current flow in power rails by amplifying the small voltage drop across a shunt resistor. These amplifiers can detect and amplify very small voltages, typically in the 10 to 100 mV range, while rejecting large common-mode voltages. Applications include power management, battery monitoring, motor control, overcurrent protection, system diagnostics, and energy measurement. Current sense amplifiers enable precise current monitoring for efficiency optimization, fault detection, and system protection. They can measure current flowing in a single direction (unidirectional) or in both directions (bidirectional) through the sense resistor, depending on the application requirements. 5. What is the difference between a voltage amplifier and a current sense amplifier?While both are amplifiers, they serve different purposes and have distinct specifications. Standard voltage amplifiers (operational amplifiers) are general-purpose devices designed to amplify signals within their power supply rails. They typically have moderate CMRR (80-90 dB), input voltage ranges limited to their supply voltages, and are not optimized for measuring very small differential voltages in the presence of large common-mode voltages.Current sense amplifiers, in contrast, are specialized devices optimized for measuring small voltage drops across shunt resistors. They feature very high CMRR (100-120 dB or higher), ultra-low input offset voltage (<50 µV), and the ability to handle common-mode voltages far exceeding their supply voltage. For example, a current sense amplifier powered by 3.3V can safely measure voltages on a 48V power rail. Current sense amplifiers use specialized input architectures that prevent ESD protection diodes from conducting when input voltages exceed supply rails, enabling them to operate in high-voltage environments. They are specifically designed for DC precision, high common-mode rejection, and wide common-mode voltage ranges—characteristics essential for accurate current measurement in power management applications. 6. How do I select the right shunt resistor value?Shunt resistor selection involves balancing several factors: voltage drop, power dissipation, and measurement accuracy. The voltage drop should be large enough for accurate measurement (typically 50-100 mV at full-scale current) but small enough to minimize power loss. Use the formula R = V / I, where V is the desired voltage drop and I is the maximum current. For example, for 1A measurement with 50 mV drop: R = 0.05V / 1A = 0.05Ω (50 mΩ). Power dissipation is calculated as P = I² × R. For 1A through 50 mΩ: P = 1² × 0.05 = 0.05W (50 mW). Select a resistor with adequate power rating (typically 2-4× calculated power) and low temperature coefficient (<50 ppm/°C) for stable measurements. Consider resistor tolerance (typically 1% or better) as it directly affects measurement accuracy. 7. What are the key advantages of high-side vs. low-side current sensing?High-side sensing places the shunt resistor between the power supply and load, maintaining ground integrity and enabling detection of all fault conditions including ground shorts. It provides better system diagnostics but requires amplifiers with high CMRR and wide common-mode voltage range. Low-side sensing places the shunt resistor between load and ground, offering simpler implementation and lower cost since common-mode voltage is near ground. However, it disrupts ground reference and cannot detect ground faults. High-side sensing is preferred for safety-critical applications, battery monitoring, and systems requiring fault detection, while low-side sensing is suitable for cost-sensitive applications where ground disruption is acceptable. 8. Can current sense amplifiers measure AC current?Yes, many current sense amplifiers can measure AC current, provided their bandwidth is sufficient for the frequency of interest. The amplifier's bandwidth must be at least 10× the highest frequency component of the AC signal for accurate measurement. For example, measuring 60 Hz AC requires minimum 600 Hz bandwidth. Most modern current sense amplifiers offer bandwidths from 100 kHz to several MHz. For AC-only measurements (where DC component is not needed), current transformers or Rogowski coils provide better performance. For combined DC and AC measurement (such as motor current with PWM ripple), use a current sense amplifier with adequate bandwidth and consider adding filtering to reduce high-frequency noise while preserving the signals of interest.

IntroductionDefinition: A ceramic capacitor is a capacitor that has a ceramic dielectric as its dielectric material. Multi-layer ceramic capacitors and ceramic disc capacitors are the two most common types. The dielectric in a ceramic capacitor is ceramic. Ceramics, a well-known insulator, is one of the first materials used in the manufacture of capacitors. Ceramic capacitors come in a variety of geometric forms, some of which have been phased out due to size, parasitic effects, or electrical characteristics, such as ceramic tubular capacitors and barrier layer capacitors. Multi-layer ceramic capacitor, also known as ceramic multi-layer chip capacitor (MLCC), and ceramic disc capacitor are the two types of ceramic capacitors most widely used in modern electronics.                                                                                                                                             Typical Multilayer Ceramic Capacitor With a production volume of about 1000 billion devices per year, MLCCs are the most widely used capacitors. Due to their small size, they are commonly used and manufactured using SMD (surface-mounted) technology. Ceramic capacitors are usually made with very small capacitance levels, ranging from 1nF to 1F, with a maximum capacitance of 100F. Ceramic capacitors are thin, and their maximum rated voltage is low. Since they lack polarity, they can be safely linked to AC electricity. Due to low parasitic effects including resistance and inductance, ceramic capacitors have excellent frequency response. Ceramic capacitors have the following advantages over other capacitors: small size, large capacity, good heat resistance, mass production suitability, and low price.CatalogIntroductionCatalogⅠThe Origin of Ceramic CapacitorsⅡ Classification of Ceramic Capacitors  2.1 Semiconductor Ceramic Capacitors  2.2 High Voltage Ceramic CapacitorsⅢ Characteristics  3.1 Precision and Tolerance  3.2 Size Advantages  3.3 High Voltage and High PowerⅣ Ceramic Dielectric TypesⅤ Construction and Properties of Ceramic Capacitors  5.1 Ceramic Disc Capacitors  5.2 Multi-layer Ceramic Capacitor (MLCC) Ⅵ Advantages and Disadvantages  6.1 Advantages  6.2 DisadvantagesⅦ Applications for Ceramic CapacitorsⅧ How to read ceramic capacitor value?Ⅸ How to Test Ceramic Disc CapacitorⅩ FAQⅠThe Origin of Ceramic CapacitorsLombardi from Italy invented ceramic dielectric capacitors in 1900. It was discovered in the late 1930s that by adding titanate to ceramics, the dielectric constant can be doubled, resulting in cheaper ceramic dielectric capacitors. Ceramic capacitors were first used in military electronic equipment around 1940, following the discovery of the insulation properties of BaTiO3 (Barium titanate), the primary raw material for today's ceramic capacitors. Around 1960, ceramic laminate capacitors became commercially available. It had become an essential part of electronic devices by 1970, thanks to the rapid growth of hybrid IC, computers, and portable electronic devices. Ceramic dielectric capacitors currently account for approximately 70% of the overall capacitor market.                                                                                                             Historic Ceramic CapacitorsⅡ Classification of Ceramic Capacitors2.1 Semiconductor Ceramic Capacitors(1)Surface Layer Ceramic CapacitorThe miniaturization of capacitors, that is, the capacitor obtains the largest possible capacity in the smallest possible volume, which is one of the development trends of capacitors. For the separation of capacitor components, there are two basic approaches to miniaturization: ①Make the dielectric constant of the dielectric material as high as possible; ②Make the thickness of the dielectric layer as thin as possible. Among ceramic materials, the dielectric constant of ferroelectric ceramics is very high, but when ferroelectric ceramics are used to manufacture ordinary ferroelectric ceramic capacitors, it is difficult to make the ceramic dielectric very thin. Firstly, due to the low strength of ferroelectric ceramics, it is difficult to carry out actual production operations because it is easy to fracture when it is thin. Secondly, when the ceramic medium is fragile, it is easy to cause various structural defects and the production process will be challenging.(2)Grain Boundary Layer Ceramic CapacitorThe surface of BaTiO3 semiconductor ceramics with sufficiently developed grains is coated with appropriate metal oxides (such as CuO or Cu2O, MnO2, Bi2O3, Tl2O3, etc.), and heat treatment is performed under oxidizing conditions at appropriate temperatures. Then the substance will form a low eutectic solution phase with BaTiO3, rapidly diffuse and penetrate into the ceramic along with the open pores and grain boundaries, forming a thin solid solution insulating layer on the grain boundaries. The resistivity of this thin solid solution insulating layer is very high (up to 1012~1013Ω·cm). Although the ceramic grain interior remains as semiconductor, the entire ceramic body is shown as the dielectric constant of 2×104 to 8×104 dielectric medium. Capacitors made with this kind of porcelain are called boundary layer ceramic capacitors, or BL capacitors for short.2.2 High Voltage Ceramic CapacitorsThe ceramic materials of high-voltage ceramic capacitors are barium titanate-based and strontium titanate-based. Barium titanate-based ceramic materials have the advantages of high dielectric coefficient and good AC withstand voltage characteristics, but also have the shortcomings of capacitance change rate with the increase of medium-temperature and decrease of insulation resistance. The Curie temperature of strontium titanate crystal is -250℃, and it is a cubic perovskite structure at room temperature.  It is a para-electric body, and there is no spontaneous polarization phenomenon. Under high voltage, the dielectric coefficient of strontium titanate ceramic material changes little. The dielectric loss tangent value (tgδ) and capacitance change rate are small, which makes it a high-voltage capacitor dielectric. 2.3 Multilayer Ceramic CapacitorsMultilayer ceramic capacitors are the most widely used type of electronic component. They are stacked alternately in parallel with the internal electrode material and ceramic body and fired into a whole, also known as chip monolithic capacitors. It has the characteristic of small size, high specific volume and high precision. It can be mounted on a printed circuit board (PCB) and hybrid integrated circuit (HIC) substrates. It can effectively reduce the volume and weight of electronic information terminal products (especially portable products), and also improve product reliability.                                                             Multilayer ceramic capacitors conform to the IT industry's development direction of miniaturization, lightweight, high performance, and multifunction. The outline of the national vision goal for 2010 clearly puts forward that new components such as surface-mounted components should be the development focus of the electronic industry. It is not only simple packaging, good sealing, and can effectively isolate the opposite electrode. MLCC can store charge, block DC, filter merge, distinguish different frequencies and tune the circuit in the electronic circuit.  It can partially replace organic film capacitors and electrolytic capacitors in high-frequency switching power supplies, computer network power supplies and mobile communication equipment. What's more, it can greatly improve the filtering performance and anti-interference performance of high-frequency switching power supplies.                                                Ⅲ Characteristics3.1 Precision and ToleranceCeramic capacitors are currently available in two classes: class 1 and class 2. When high stability and low losses are needed, Class 1 ceramic capacitors are used. They are extremely precise, and the capacitance value remains constant regardless of applied voltage, temperature, or frequency. Within a total temperature range of -55 to +125 °C, the capacitance thermal stability of the NP0 series of capacitors is 0.54%. The nominal capacitance value's tolerances can be as poor as 1%. Class 2 capacitors have a large capacitance per volume and are used in less sensitive applications. Their thermal stability in the operating temperature range is usually 15%, and nominal value tolerances are about 20%.3.2 Size AdvantagesMLCC devices outclass other capacitors when high component packing densities are needed, as is the case in most modern printed circuit boards (PCBs). The “0402 multi-layer ceramic capacitor package” measures just 0.4 mm x 0.2 mm to demonstrate this point. There are 500 or more ceramic and metal layers in such a box. As of 2010, the minimum ceramic thickness was on the order of 0.5 microns.3.3 High Voltage and High PowerCeramic capacitors that are physically bigger and can withstand even higher voltages are known as power ceramic capacitors. These are much larger than the ones used on PCBs, and they have specialized terminals for connecting to a high-voltage supply safely. Ceramic capacitors with a power specification of much more than 200 volt-amperes can withstand voltages ranging from 2 kV to 100 kV. Printed circuit boards use smaller MLCCs that are rated for voltages ranging from a few volts to several hundreds of volts, depending on the application.Ⅳ Ceramic Dielectric TypesUnlike other capacitor types such as tantalum capacitors and electrolytic capacitors, ceramic capacitors may use a variety of dielectrics. These various dielectrics give capacitors very different properties, so in addition to deciding on a ceramic capacitor, a second decision about the type of dielectric may be needed. Popular ceramic capacitor dielectrics, such as C0G, NP0, X7R, Y5V, Z5U, and many others, are frequently listed in distributors' lists. However, determining which form is best necessitates a little more study. Ceramic Capacitor Dielectric ClassesSome industry organizations have identified a range of ceramic dielectric application classes to make selecting capacitors with the appropriate dielectric easier. These application groups divide the various ceramic capacitor dielectrics into separate classes based on the anticipated application.     International bodies such as the IEC (International Electrotechnical Commission) and the EIA (Electronic Industries Alliance) have standardized these ceramic capacitor classes.Ⅴ Construction and Properties of Ceramic Capacitors5.1 Ceramic Disc CapacitorsCeramic disc capacitors are made by coating a ceramic disc on both sides with silver contacts. These devices can be constructed from several layers to achieve higher capacitances. Ceramic disc capacitors are usually through-hole components that have lost popularity due to their large scale. If capacitance values allow, MLCCs are used instead. Ceramic disc capacitors have capacitance values ranging from 10pF to 100pF and voltage ratings ranging from 16 volts to 15 kV and beyond.                                                                    5.2 Multi-layer Ceramic Capacitor (MLCC)MLCCs are made by combining finely ground granules of paraelectric and ferroelectric materials and layering the mixture with metal contacts alternately. Following the layering, the device is heated to a high temperature and the mixture sintered, yielding a ceramic substance with the desired properties. The capacitance of the resulting capacitor is increased by connecting several smaller capacitors in parallel. MLCCs are made up of 500 layers or more, with a minimum layer thickness of 0.5 microns. As technology advances, layer thickness decreases, allowing for higher capacitances in the same volume.Ⅵ Advantages and Disadvantages6.1 AdvantagesThe following are some of the benefits of using a ceramic capacitor:• This capacitor's physical structure is very compact.• It is well suited for the application of AC signals due to its non-polarized nature.• Signal interference suppression, such as radiofrequency suppression and electromagnetic interference suppression, is improved with these capacitors.• This capacitor is reasonably priced, and it can withstand voltages of up to 100 volts.6.2 DisadvantagesThe following are the drawbacks of using these capacitors:• The capacitance value of these capacitors is less than one microfarad.• These components are also responsible for the Microphonic effect in circuits.• It is unable to withstand high voltages. Since it can easily impact the dielectric present in it. As a consequence, there is a breakdown.Ⅶ Applications for Ceramic CapacitorsGiven that MLCCs are the most commonly manufactured capacitor in the electronics industry, it should come as no surprise that they have a wide range of applications. A resonant circuit in transmitter stations is an interesting high-precision, high-power application. High-voltage laser power supplies, power circuit breakers, and induction furnaces all use Class 2 high-power capacitors. Small-form SMD (surface mount) capacitors are commonly used in printed circuit boards, and capacitors the size of a grain of sand are used in high-density applications. They're also used in DC-DC converters, where high frequencies and high levels of electrical noise put a lot of strain on the components. Since ceramic capacitors are non-polarized and come in a wide range of capacitances, voltage ratings, and sizes, they can be used as a general-purpose capacitor. Ceramic disc capacitors, which are used throughout brush DC motors to reduce RF noise, are familiar to many hobbyists, especially in the field of robotics.Ⅷ How to read ceramic capacitor value?Ceramic capacitors normally have three digits for their values, such as 102, 103, and 101, and the values are in Pico farads. The numbering scheme is simple to understand if you note that picofarads, not microfarads, are used.The worth of a ceramic capacitor with three digits – ABC is AB*10^C Pico Farad. The digit 104 means 10*104pF = 100000pF = 100nF = 0.1uF if ABC is 104. The first two digits of the printed code correspond to the first two digits of the capacitor value, while the third digit indicates the number of zeroes that must be applied to convert the capacitor value to Pico Farad. If we calculate in Nano Farad for values ending with 4, then the reading becomes easy like 104 is 100nF. If we calculate in Nano Farad for values ending with 3, then the reading becomes easy like 103 is 10nF.Some ceramic capacitors are polarized, meaning they have both positive and negative terminals. The capacitor can be identified by its tolerance in addition to its capacitance value. There is many tolerance marking schemes in use, with one and two alphabets being the most common. You don't need to recall them unless you're dealing with a precise circuit. We only looked at ceramic capacitors in direct current (DC) circuits with voltages ranging from 12V to near zero in this short article. Hobbyists are familiar with this collection. It is also useful to be familiar with the tolerance marking scheme for professional purposes. Ⅸ How to Test Ceramic Disc CapacitorCeramic disc capacitors are units used in the computer industry to control voltage for various dielectric functions. Ceramic layers aim to dissipate heat generated by high voltage while also protecting the environment — both internal and external — from damage. Volumetric efficiency is inversely proportional to stability and accuracy with these capacitors, making testing difficult.Step 1 Ceramic capacitors must be tested since they will short out if they are exposed to high voltage. Your monitor can blink or go blank if this happens. This issue can be resolved by removing all of the ceramic capacitors. Ceramic capacitors, on the other hand, can be tested if you have the right tools. Step 2To measure a ceramic capacitor, use a wireless multimeter. The capacitor works properly when the voltage is constant. However, you won't be able to accurately calculate it if the ohmmeter's output and digital capacitance don't match the capacitor's voltage, so the second option is preferable. Step 3To locate the short circuit or assess cases where optical capacitance meters fail to produce shortened readings, use an analog insulation tester. In order to obtain a 12-volt output, set the analog meter to 10 Kohm. This phase is needed for the ceramic capacitor to be tested. You may also use both methods to improve measurement precision if you do want to stop removing the capacitor and test it aboard.Related recommendation: How to Test a Start Capacitor?                                             How to Discharge a Capacitor? Ⅹ FAQ1. What is Ceramic Capacitor?A fixed value type of capacitor where the ceramic material within the capacitor acts as a dielectric is the Ceramic Capacitor. This capacitor consists of more alternating layers with ceramic and also a metal layer which acts as an electrode. The composition of this ceramic material in this capacitor tells about the electrical behavior along with its applications. We can define a ceramic capacitor as A fixed-value capacitor where the ceramic material acts as the dielectric. 2. What are the advantages of ceramic capacitors?Following are the advantages of ceramic capacitors:Manufacturing cost is lessHigh-frequency performance is exhibitedThe stability of the capacitor is dependent on the ceramic dielectric 3. What is the capacitance range for a ceramic capacitor?The typical capacitance range for a ceramic capacitor is 10 pF to 0.1 μF. 4. Can I replace all electrolytic capacitors with ceramic ones?If you can find ceramic capacitors of the correct value, you can certainly do this. Ceramic capacitors are more stable, have a longer useful lifetime, have higher voltage ratings and are not polarized. Be prepared to find that there will be a substantial size difference. 5. What are the differences between electrolytic, tantalum and ceramic capacitors?Ceramic capacitors don't have polarity, their terminals can be interchanged. They are suitable for both ac and dc. They don't have any chemical reaction involved in their work. They have a lesser capacity for the same given size. Electrolytic capacitors have polarity (i.e. they have fixed positive and negative terminal), Suitable for dc only. A chemical reaction involves the formation of aluminum oxide on the electrode. ( Consists of aluminum electrodes in a solution of Ammonium borate).Higher capacity. A tantalum electrolytic capacitor, a member of the family of electrolytic capacitors, is a polarized capacitor whose anode electrode (+) is made of tantalum on which a very thin insulating oxide layer is formed, which acts as the dielectric of the capacitor. A solid or liquid electrolyte that covers the surface of the oxide layer serves as the second electrode (cathode) (-) of the capacitor. 6. What is the time constant for the discharge of the capacitors in (figure 1)?figure 1The equivalent resistance:R= 2*1× 10∧3 = 2000 i©=> the time constant: T= R*C = 2000*1× 10∧-6 = 2×10∧-3s = 2ms 7. How do you read a ceramic capacitor value?The first two digits, in this case, the 10 give us the first part of the value. The third digit indicates the number of extra zeros, in this case, 3 extra zeros. So the value is 10 with 3 extra zeros, or 10,000. Ceramic disc capacitor codes are always measured in pico Farads or pF. 8. How can you tell if a ceramic capacitor is bad?Use the multimeter and read the voltage on the capacitor leads. The voltage should read near 9 volts. The voltage will discharge rapidly to 0V because the capacitor is discharging through the multimeter. If the capacitor will not retain that voltage, it is defective and should be replaced. 9. Do ceramic capacitors degrade over time?Among ceramic capacitors, the capacitance, especially of capacitors classified as a high dielectric constant (B/X5R, R/X7R characteristics), decreases over time. ... When the capacitor cools down below the Curie point, aging starts again. 10. How do you tell the positive and negative of a ceramic capacitor?In general, the ceramic capacitor has no positive and negative poles, and the capacity is generally small. It is often used for signal source filtering, and the polarity is only temporary behavior. This is a kind of non-polar electrolytic capacitor, so it is not polar. 

Executive Summary: 2026 MOV GuideWhat is an MOV? A Metal Oxide Varistor (MOV) is the industry-standard component used to protect electronic circuits from high-voltage surges and transient spikes.Key Function: It acts as a voltage-dependent switch—normally maintaining high resistance, but switching to low resistance within nanoseconds during a spike to shunt destructive energy away from sensitive components.2026 Standard: Modern circuit design mandates sizing MOVs based on Clamping Voltage, Peak Pulse Current, and Energy Rating (Joules) to ensure compliance with IEC and UL safety standards.What Is the Role of MOVs in Circuit Protection?The role of an MOV in circuit protection is to act as the critical first line of defense against destructive voltage transients by shunting excess electrical energy away from sensitive components. The blue or orange circular component typically found on the AC input side of a power supply circuit is a Metal Oxide Varistor, or MOV. As of 2026, the MOV remains indispensable in modern electronics, supporting a global surge protection device market projected to exceed $4.5 billion. It functions as a specialized variable resistor that automatically adjusts its resistance based on voltage levels. Under normal conditions, it does nothing; however, when high current or voltage spikes occur, the MOV instantaneously decreases its resistance to function as a short circuit. To fully protect circuits from catastrophic failure, MOVs are almost exclusively used in combination with a fuse. In this updated guide, we will explore the engineering principles behind MOVs, their electrical characteristics, and how to select the precise component for robust 2026 circuit designs.What Is a Metal Oxide Varistor (MOV)?A Metal Oxide Varistor (MOV) is a bidirectional, non-linear surge protection component that shunts excessive current to the ground during a voltage spike. Unlike manual potentiometers, MOVs adjust their resistance automatically and nearly instantaneously (typically in under 25 nanoseconds). As the voltage across the device increases, its resistance decreases drastically. This inverse relationship is the core mechanism that shields sensitive microcontrollers and power ICs from mains surges. A standard radial lead MOV used in consumer electronics is depicted below.Protection ComponentEnergy HandlingResponse TimePrimary ApplicationMOV (Metal Oxide Varistor)High (Joules)< 25 nsAC Mains & Power SuppliesTVS DiodeLow to Medium< 1 nsDC Data Lines & MicroprocessorsGDT (Gas Discharge Tube)Very High> 1 µs (Slow)Telecommunications & Heavy IndustrialHow Does a MOV Work?An MOV works by maintaining a high-resistance state during normal voltages and rapidly switching to a low-resistance state when a voltage spike exceeds its clamping threshold. Under normal operating voltage, the MOV maintains extremely high resistance (Mega-ohms), drawing negligible current and acting as an open circuit. However, when a transient spike exceeds the specific "clamping voltage" (or knee voltage), the MOV's semiconductor structure undergoes an avalanche breakdown. It rapidly switches to a low-resistance state, drawing the surge current and dissipating the excess energy as heat, thereby clamping the voltage to a safe level for downstream equipment. Critical Limitation: MOVs are designed to handle short-duration transients (microseconds), not sustained over-voltage conditions. Repeated exposure to high-energy surges degrades the internal zinc oxide structure. Over time, the clamping voltage drifts lower, eventually leading to thermal runaway or failure. To mitigate this risk in 2026 standard designs, MOVs are often placed in series with a thermal cutoff (TCO) or fuse that disconnects the circuit if the MOV overheats.How Are MOVs Integrated into Electrical Circuits?MOVs are universally connected in parallel to the circuit they protect, usually situated immediately after the safety fuse but before the transformer or rectifier. The diagram below illustrates the standard topology for AC mains protection. Operational Flow:Normal State: Voltage is within rated limits. The MOV has high resistance. Current flows to the load; no current flows through the MOV.Surge Event: A lightning strike or grid switching causes a voltage spike. The voltage appears directly across the parallel MOV.Clamping Action: The high voltage forces the MOV into a conductive state (low resistance). It effectively shorts the lines. This "short circuit" action draws a massive surge of current. If the surge is significant, this current rush blows the safety fuse, physically isolating the circuit from the mains. While the MOV sacrifices itself (and often the fuse) during catastrophic events, it saves the expensive components (logic boards, motors) downstream. If you find a burnt MOV in a power supply, it indicates it successfully did its job by absorbing a lethal voltage spike.What Materials Are Used to Construct an MOV?The Metal Oxide Varistor is a sintered ceramic component composed primarily of Zinc Oxide (ZnO) grains (approximately 90%), doped with other metal oxides such as cobalt, manganese, and bismuth. These ceramic powders are sandwiched between two metal plates (electrodes) and encapsulated in an epoxy resin. Microscopic Function: The grain boundaries between zinc oxide crystals act as miniature P-N junction diodes. Essentially, a single MOV functions as millions of back-to-back Zener diodes connected in series and parallel. At low voltage, the reverse leakage current is minimal. When high voltage is applied, electron tunneling and avalanche breakdown occur at these grain boundaries, allowing massive current flow.MOVs are manufactured in various form factors including radial discs (most common), axial leads, and high-energy blocks. For heavy industrial applications requiring massive power handling, multiple MOVs are connected in parallel. Conversely, they are connected in series to achieve higher voltage ratings.What Are the Key Electrical Characteristics of an MOV?To interpret a datasheet in 2026, engineers must understand the specific behavior of MOVs under static and dynamic conditions, specifically focusing on static resistance, the V-I clamping curve, and parasitic capacitance.A. Static ResistanceThe resistance of an MOV is not fixed. The graph below plots Resistance (Y-axis) against Voltage (X-axis).As shown, resistance is highest at the rated operating voltage. As voltage climbs toward the clamping threshold, resistance plummets logarithmically, allowing current conduction. B. V-I Characteristics (The Clamping Curve)Unlike a linear resistor (Ohm's Law), the MOV follows a non-linear VI curve, similar to two back-to-back Zener diodes.Leakage Region (0V to ~200V): High resistance. Current is in micro-amperes ($\mu$A).Conducting Region (200V to 250V): As voltage enters the breakdown region, current rises to milli-amperes.Clamping Region (>250V): The device becomes highly conductive. Current jumps to Amperes, clamping the voltage to protect the circuit. C. Parasitic CapacitanceBecause an MOV consists of two electrodes separated by a dielectric, it acts as a capacitor. This parasitic capacitance (ranging from pF to nF) is negligible for DC or mains frequency (50/60Hz) power circuits. However, for high-frequency data lines, this capacitance can attenuate signals. Reactance is calculated as $X_c = 1 / (2\pi f C)$. Engineers must select low-capacitance varistors for high-speed data protection.How to Select the Right MOV (2026 Selection Guide)Selecting the correct MOV requires matching the device specifications to your circuit's voltage and surge requirements. Use the following parameters as your checklist:Maximum Continuous Operating Voltage (MCOV): The highest RMS or DC voltage the device can withstand continuously without conducting. Rule of Thumb: Select an MCOV 10-20% higher than your actual line voltage (e.g., use a 150V or 275V rated MOV for 120V/240V lines respectively).Clamping Voltage ($V_c$): The voltage level where the MOV "locks" or clamps during a surge. This must be lower than the maximum withstand voltage of the components you are protecting.Surge Current Rating ($I_{max}$): The maximum peak current the MOV can handle for a specific pulse duration (usually 8/20 $\mu$s). Higher is always better for longevity.Energy Absorption (Joules): The maximum energy the MOV can dissipate in a single event. A higher Joule rating means the MOV can absorb larger or longer transients without failing.Response Time: Modern MOVs respond in nanoseconds (typically < 25ns), which is sufficient for lightning and switching surges.Degradation Factor: Every surge absorbed slightly degrades the MOV's V-I curve. In 2026 designs, over-specifying the Energy and Current ratings extends the lifespan of the protection circuit.Where Are MOVs Commonly Used?MOVs are commonly used in AC power strips, switch-mode power supplies, and telecommunications equipment to suppress transient voltage spikes. They are versatile and found in nearly all power electronic devices.Key Applications:Power Strips & Surge Protectors: The most common consumer application.Power Supplies (SMPS): Connected across AC mains (Line-Neutral) to stop grid spikes.Motor Control: Protecting MOSFETs and Thyristors from back-EMF and switching arcs.Telecommunications: Protecting lines from lightning induction (often using low-capacitance variants).Consumer Electronics: Laptops, LED drivers, and chargers.How Do You Design a Robust MOV Protection Circuit?To design a robust protection circuit, engineers must strategically balance voltage margins, energy ratings, and fail-safe mechanisms. Here are professional design tips for integrating MOVs into 2026-era electronics: 1. Voltage Margin Strategy: Never match the MOV voltage rating exactly to the line voltage. For a 230V AC line, a 275V AC rated MOV is standard practice. This buffer prevents the MOV from conducting during minor, harmless voltage fluctuations, which would overheat the device over time. 2. Energy Calculation: Estimate the worst-case surge energy. If your environment is prone to heavy industrial switching or lightning, prioritize the **Joule rating**. A physically larger MOV (disk diameter) generally handles more energy. 3. The "Fail-Safe" Requirement: When an MOV fails, it often fails as a short circuit. If not fused properly, this can cause a fire. ALWAYS place a fuse upstream of the MOV. Modern designs often use a "Thermally Protected MOV" (TMOV) which contains an integrated thermal fuse that opens if the MOV overheats due to sustained overvoltage. 4. Parallel Configuration: For extremely high reliability, engineers place multiple MOVs in parallel to split the surge current, though this requires matched VI characteristics to ensure even current sharing.Frequently Asked QuestionsWhat is the difference between an MOV and a TVS diode?A Metal Oxide Varistor (MOV) handles massive energy surges (Joules) and high currents, making it ideal for AC mains protection. In contrast, a Transient Voltage Suppressor (TVS) diode responds faster and clamps at precise voltages, making it better suited for protecting low-voltage DC data lines and sensitive microprocessors.How do you test if a Metal Oxide Varistor is blown?To test an MOV, disconnect power and use a digital multimeter set to resistance (Ohms). A healthy MOV should read as an open circuit with infinite resistance. If the multimeter reads zero or very low resistance, the MOV has shorted internally and must be replaced immediately to restore protection.Can an electrical circuit work without an MOV?Yes, a circuit will function normally without an MOV because the device operates in parallel and draws no current under standard conditions. However, operating without one leaves the circuit completely vulnerable to voltage spikes, meaning a single power surge could instantly destroy the downstream components.Why does an MOV blow the fuse during a surge?An MOV is designed to drop its resistance to near zero during a high-voltage spike, creating a deliberate short circuit. This sudden short draws a massive influx of current from the mains, which intentionally overloads and blows the upstream fuse, physically disconnecting the circuit from the dangerous power source.{"@context": "https://schema.org","@graph":[{"@type": "Article","headline": "Metal Oxide Varistor (MOV): The 2026 Guide to Circuit Protection","description": "A comprehensive guide to Metal Oxide Varistors (MOVs). 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IntroductionThermal relay is a protective device.  are protective devices. It is used in conjunction with a contactor to protect electric motors. The basic working principle of thermal relay is that, when a bimetallic strip is heated up by a heating coil carrying over current of the system, it bends and makes normally open contacts. Getting to know more about the thermal basics just check the following note. CatalogIntroductionⅠ The Working Principle and Structure of Thermal Relay  1.1 The Role and Classification of Thermal Relay  1.2 Protection Characteristics and Working Principle of Thermal RelayⅡ Selection and Setting Principle of Thermal Relay  2.1 Thermal Relay Selection Overview  2.2 Type Selection of Thermal Relay  2.3 Selection of Rated Current of Thermal Relay  2.4 Selection of Thermal Element Setting Current  2.5 Reliable and Reasonable Protection Characteristics of The Thermal Relay  2.6 Other ConsiderationsⅢ Other Matters Needing Attention  3.1 Installation Direction  3.2 Selection of Connecting Wires  3.3 Use Environment  3.4 Adjustment of Thermal RelayⅣ Frequently Asked Questions about Thermal RelayⅠ The Working Principle and Structure of Thermal Relay1.1 The Role and Classification of Thermal RelayIn the electric drag control system, when the three-phase AC motor runs under abnormal conditions such as long-term under-load and under-voltage operation, long-term overload operation, and long-term single-phase operation, it will cause the motor winding to overheat and even burn out. In order to give full play to the overload capacity of the motor, to ensure the normal start and operation of the motor, and once the motor is overloaded for a long time, it can automatically cut off the circuit, so that there are electrical appliances that can change the operating time with the degree of overload and that is thermal relay.  Obviously, the thermal relay is used for overload protection of the three-phase AC motor in the circuit. It must be pointed out that, due to the thermal inertia of the heating elements in the thermal relay, instantaneous overload protection cannot be done in the circuit, and short circuit protection cannot be done either. Therefore, it is different from overcurrent relays and fuses. According to the number of phases, there are three types of thermal relays: single-phase, two-phase, and three-phase. Each type has different specifications and model numbers according to the rated current of the heating element. Three-phase thermal relays are often used in three-phase AC motors for overload protection. Divided by function, there are two types of three-phase thermal relay. One is without phase failure protection and the other one is with phase failure protection.1.2 Protection Characteristics and Working Principle of Thermal Relay1) Protection Characteristics of Thermal Relay Because the contact action time of the thermal relay is related to the overload of the motor being protected, before analyzing the working principle of the thermal relay, the relationship between the motor's overload current and the motor's energizing time must be clarified under the condition that the motor does not exceed the allowable temperature rise. This relationship is called the overload characteristic of the motor. When an overload current occurs during the motor operation, it will inevitably cause the winding to heat up. According to the thermal equilibrium relationship, it is not difficult to draw the conclusion that under the condition of allowable temperature rise, the motor energizing time is inversely proportional to the square of its overload current. According to this conclusion, it can be concluded that the motor's overload characteristics have inverse time characteristics, as shown by curve 1 in Figure 1. Figure 1. Overload Characteristics of the Motor and Protection Characteristics of the Thermal Relay and Their Coordination In order to adapt to the overload characteristic of the motor and play the role of overload protection, it is required that the thermal relay should also have the inverse time characteristic as the motor overload characteristic. For this reason, the thermal relay must have a resistance heating element. The thermal effect generated by the overload heating current through the resistance heating element causes the sensing element to act, thereby driving the contact to complete the protection function.  The relationship between the overload current passed in the thermal relay and the action time of the thermal relay contact is called the protection characteristic of the thermal relay, as shown by curve 2 in figure 1. Considering the effects of various errors, the overload characteristics of the motor and the protection characteristics of the relay are not a curve, but a belt. Obviously, the larger the error, the wider the belt; the smaller the error, the narrower the belt. It can be known from the curve 1 in the figure that when the motor is overloaded, it is safe to work below the curve 1. Therefore, the thermal relay's protection characteristics should be close to the motor's overload characteristics. In this way, if an overload occurs, the thermal relay will operate before the motor reaches its allowable overload limit, cutting off the power to the motor to prevent damage. 2) Working Principle of Thermal Relay The heat-generating heating element in the thermal relay should be connected in series with the motor circuit. In this way, the thermal relay can directly reflect the overload current of the motor. The sensing element of a thermal relay generally uses a bimetal. The so-called bimetallic sheet is to mechanically roll two metal sheets with different linear expansion coefficients into one body. The larger the expansion coefficient is called the active layer, the smaller the expansion coefficient is called the passive layer. The bimetallic sheet undergoes linear expansion when heated. Because the linear expansion coefficients of the two layers of metal are different and the two layers of metal are closely attached together, the bimetallic sheet is bent to the passive layer side, and the mechanical force generated by the bending of the bimetallic piece drives the contact action. There are four types of bimetal heating methods, namely direct heating, indirect heating, composite heating, and current transformer heating. The direct heating type uses the bimetal as a heating element and allows current to pass through it directly; the heating element of the indirect heating type is made of resistance wire or tape, is wound around the bimetal and is insulated from the bimetal; the composite heating type is between the above two methods; the heating element of the current transformer heating type is not directly connected to the motor circuit, but is connected to the secondary side of the current transformer. This method is mostly used in situations where the motor current is relatively large to reduce the current passes through the heating element. Figure 2. Structural Schematic of the Thermal Relay The thermal element 3 is connected in series to the motor stator winding, and the motor winding current is the current flowing through the thermal element. When the motor is running normally, although the heat generated by the thermal element can bend the bimetal 2, it is not enough to make the relay operate; when the motor is overloaded, the heat generated by the thermal element increases, causing the bending displacement of the bimetal to increase.  After a certain period of time, the bimetal is bent to push the guide plate 4, and the contacts 9 and 6 are separated by the compensating bimetal 5 and the push rod 14, the contacts 9 and 6 are normally-closed contacts in which the thermal relay is connected to the contactor coil circuit, and the contactor is de-energized after being disconnected. The normally-open contacts of the contactor disconnect the power supply of the motor to protect the motor. The adjusting knob 11 is an eccentric wheel, which constitutes a lever with the support 12, and 13 is a compression spring. Turning the eccentric wheel and changing its radius can change the contact distance between the compensating bimetal 5 and the guide plate 4 so that the purpose of adjusting the setting action current is achieved. In addition, the position of the normally-open contact 7 is changed by adjusting the reset screw 8 so that the thermal relay can work in two working states: manual reset and automatic reset. When debugging the manual reset, after the fault is excluded, button 10 must be pressed to restore the movable contact to the contact position of the static contact 6. 3) Thermal Relay with Open Phase Protection One of the main reasons for a three-phase asynchronous motor to burn out is that wiring of a three-phase motor is loosened or a phase fuse is blown. If the motor protected by the thermal relay is Y connection method when one phase power failure occurs in the line, the current of the other two phases will increase a lot. Since the line current is equal to the phase current, the current flowing through the motor windings and the current flowing through the thermal relay are increased by the same proportion, so ordinary two-phase or three-phase thermal relays can protect this.  If the motor is △ connection method, the phase current and line current of the motor will not be the same when the phase failure occurs, the current flowing through the motor windings and the current flowing through the thermal relay will increase in different proportions, and the thermal element is connected in series with the power supply line of the motor, and it is set according to the rated current of the motor, that is, the line current, and the setting value is relatively large. When the fault line current reaches the rated current, in the motor winding, the fault current of the phase winding with the larger current will exceed the rated phase current, and there is a danger of overheating and burning. Therefore, the △ connection method must use a thermal relay with phase failure protection. The thermal relay with phase failure protection is a differential mechanism added to the ordinary thermal relay to compare the three currents. The structural principle of the differential phase-open protection device is shown in figure 3. The guide plate of the thermal relay is changed to a differential mechanism, which is composed of an upper guide plate 1, a lower guide plate 2 and a lever 5. They are connected by a rotating shaft. Figure 3a shows the positions of the components of the mechanism before power is applied. Figure 3b shows the position during normal energization. At this time, the three-phase bimetals are bent to the left by heating, but the bending deflection is not enough. Therefore, the lower guide plate is moved to the left for a short distance, and the relay does not operate. Figure 3c shows the situation when the three phases are overloaded simultaneously. The three-phase bimetal is bent to the left at the same time, and the lower guide plate 2 is pushed to move to the left. The normally-closed contact is immediately measured by lever 5. Figure 3 shows the disconnection of phase C.  At this time, the phase C bimetal gradually cools down, the end moves to the right and pushes the upper guide plate 1 to the right. While the temperature of the other two-phase bimetals rises, the ends are bent to the left, pushing the lower guide plate 2 to continue to move to the left. Because the upper and lower guide plates move left and right, a differential function occurs, and the normally-closed contacts are opened by the amplification of the lever. Due to the differential function, the thermal relay is accelerated to protect the motor when the phase failure occurs. Figure 3. Schematic Diagram of Differential Relay Phase Failure Protection Mechanism of Thermal Relay Ⅱ Selection and Setting Principle of Thermal Relay2.1 Thermal Relay Selection OverviewThe thermal relay is mainly used to protect the motor from overload. In order to ensure that the motor can obtain both necessary and sufficient overload protection, it is necessary to fully understand the performance of the motor, and assign it with a suitable thermal relay to perform the necessary settings. Generally, conditions related to the motor are the working environment, starting current, load nature, working system, allowable overload capacity and so on. In principle, the ampere-second characteristic of the thermal relay should be as close as possible or even overlap the motor's overload characteristic, or under the motor's overload characteristic, and at the same time, the thermal relay should not be affected (not actuated) at the moment when the motor is temporarily overloaded and started. The correct selection of the thermal relay is closely related to the working system of the motor. When the thermal relay is used to protect the motor for long-term or intermittent long-term operation, it is generally selected according to the rated current of the motor. For example, the setting value of the thermal relay may be equal to 0.95-1.05 times of the rated current of the motor, or the median value of the setting current of the thermal relay is equal to the rated current of the motor, and then adjust. When the thermal relay is used to protect a motor that is repeatedly operated for a short time, the thermal relay has only a certain range of adaptability. If there are many operations per hour, a thermal relay with a speed saturation current transformer must be selected. For special working motors with frequent forward and reverse phase on and off, it is not appropriate to use thermal relays as overload protection devices. Instead, use temperature relays or thermistors embedded in the motor windings to protect them.2.2 Type Selection of Thermal RelayThe thermal relay can be divided into the two-pole types and three-pole types from the structural type. The three-pole type is divided into phase-open protection and no phase-open protection, which should be selected according to the stator wiring of the protected motor. When the motor stator winding is in delta connection, a three-pole thermal relay with phase failure protection must be used; for a motor using the star connection method, a thermal relay without phase failure protection is generally used. Because the general motor does not have a neutral wire when using the star connection method, the two-pole or three-pole type of the thermal relay can be used. However, if the motor is set to use a star connection method with a neutral wire, the thermal relay must use a three-pole type. In addition, generally a two-phase structure thermal relay should be selected for light-load starting, long-term working motors or intermittent long-term working motors; when the current and voltage balance of the motor is poor, the working environment is poor, or there are fewer people to look after, three-phase thermal relay can be used.2.3 Selection of Rated Current of Thermal Relay1) Ensure the normal operation and starting of the motorIn the case of normal starting current and starting time and infrequent starting, it must be ensured that the starting of the motor does not cause the thermal relay to malfunction. When the starting current of the motor is 6 times the rated current, the starting time does not exceed 6s, and rarely starts continuously, the thermal relay can generally be selected according to the rated current of the motor. (In practice, the rated current of the thermal relay can be slightly larger than the rated current of the motor) 2) Consider the object of protection-the characteristics of the motorModels, specifications, and characteristics of motors. The insulation materials of motors are classified into A, E, and B grades. Their allowable temperature rises are different, so their ability to withstand overload is also different, which should be paid attention to when selecting a thermal relay. In addition, the open-type motor is easier to dissipate heat, while the closed-type motor is much more difficult to dissipate heat. With a slight overload, its temperature rise may exceed the limit. Although the selection of the thermal relay is based on the rated current of the motor in principle, the rated current of the thermal relay (or thermal element) that it is equipped with should be appropriately small for the motor with poor overload capacity. In this case, the rated current of the thermal relay (or thermal element) can also be taken as 60% -80% of the rated current of the motor. 3) Consider load factorsIf the nature of the load is not allowed to stop, even if the overload will shorten the life of the motor, the motor should not be allowed to trip unexpectedly, so as not to suffer a huge loss many times higher than the price of the motor. At this time, the rated current of the relay can be selected to a larger value (of course, the selection of the motor under this working condition generally also has a strong overload capacity). In this case, it is best to use the protective measures of the organic combination of thermal relays and other protective appliances, and only consider tripping when a very dangerous overload occurs. In short, this is not a dogmatic formula and should be considered comprehensively. 2.4 Selection of Thermal Element Setting CurrentAccording to model number of the thermal relay and the rated current of the thermal element, the adjustment range of the setting current of the thermal element can be found out. Generally, the setting current of the thermal relay is adjusted to the rated current of the motor; for motors with poor overload capacity, the setting value of the thermal element can be adjusted to 0.6-0.8 times of the rated current of the motor; when the motor starts for a long time, drags the impact load or is not allowed to stop, the setting current of the thermal element can be adjusted to 1.1-1.15 times of the rated current of the motor. 2.5 Reliable and Reasonable Protection Characteristics of The Thermal RelaySpecifically, it should have an inverse time characteristic similar to the allowable overload characteristic of the motor, and it should be below the allowable overload characteristic of the motor, and it should have high accuracy to ensure the reliability of the protective action. 2.6 Other Considerations1) Operating frequency: When the operating frequency of the motor exceeds the operating frequency of the thermal relay, such as the motor's reverse braking, reversible operation, and dense on-off, the thermal relay cannot provide protection. At this time, you can consider using a semiconductor temperature relay for protection. 2) It is not necessary to set overload protection for motors with short working hours and long intervals (such as rocker lifting motors for rocker drilling machines, etc.), and motors that have little possibility of overload despite long-term work(such as exhaust fans, etc.). 3) Thermal relays are generally not suitable for motors with a jog, heavy load starting, continuous forward and reverse rotation, and reverse braking. 4) It should have a certain temperature compensation: due to the change in the temperature of the surrounding medium, under the same overload current, the operation of the thermal relay will cause an error. To eliminate this error, temperature compensation measurements should be set up. 5) In general, the principle that the protected motor should not restart automatically even after the thermal relay is automatically reset after the thermal relay protection action, otherwise, the thermal relay should be set to the manual reset state. This is to prevent the motor from being repeatedly restarted several times to damage the equipment before the fault is eliminated.  For example: Generally, for the control circuit using button control to manually start and stop, the thermal relay can be set to the automatic reset form; for the automatic start circuit using automatic component control, the thermal relay should be set to the manual reset form; Any thermal relay that can be automatically reset should be able to be automatically reset reliably within 5 minutes after operation, while the manual reset one should be reset reliably when the manual reset button is pressed by hand within 2 minutes after the operation. Most products generally have both manual and automatic reset methods and can be adjusted to any method with screws to meet the needs of different occasions. 6) The operating current value should be adjustable to meet the needs in production and use, and reduce the specification-grade, so the thermal relay of a certain specification should be able to be realized by adjusting the cam. 7) Since it takes time for the thermal element to deform due to heat, the thermal relay can only be used as overload protection for the motor, not as short circuit protection. Therefore, when using a thermal relay, a fuse should be installed as short circuit protection. For heavy load, frequent-starting large-capacity important motors, overcurrent relays (time-delay action type) can be used for its overload and short circuit protection. Ⅲ Other Matters Needing Attention3.1 Installation DirectionThe installation direction of the thermal relay is easily overlooked. In the thermal relay, there is a current that generates heat through the heating element, which promotes the action of the bimetal. There are three ways of heat transfer: convection, radiation and conduction. Convection is directional, and heat is transferred from the bottom up. During the placement, if the heating element is under the bimetal, the bimetal will heat up quickly and the action time will be short; if the heating element is next to the bimetal, the bimetal will heat slowly and the action time of the thermal relay will be long.  When the thermal relay is installed with other electrical appliances, it should be installed below the electrical appliances and away from other electrical appliances by more than 50 mm to avoid the influence of other electrical appliances. The installation direction of the thermal relay should be in accordance with the specifications of the product manual to ensure that the thermal relay's operating performance is consistent during use.3.2 Selection of Connecting WiresThe connecting wires at the output end should be selected according to the rated current of the thermal relay. Too thick or too thin will also affect the normal operation of the thermal relay. If the connecting wire is too thin, the heat generated by the connecting wire will be transferred to the bimetallic sheet, and the heat-generating component will dissipate less heat along the wire, which shortens the trip time of the thermal relay.  On the contrary, if the connecting wire is too thick, this will extend the trip time of the thermal relay. For thermal relays with a rated current of 10 A, the cross-sectional area of the connecting wire at the output end is preferably 2.5 mm2 (single-strand copper-core plastic wire), the one of 20 A is preferably 4 mm2 (single-strand copper-core plastic wire), 16 mm2 is suitable for the one of 60 A(multi-strand copper-core rubber flexible wire), and the one of150 A is preferably 35 mm2 (multi-strand copper-core rubber flexible wire).  Because the material and thickness of the wire will affect the heat conduction from the termination of the thermal element to the external heat, if the wire is too thin, the axial thermal conductivity is poor, and the thermal relay may act in advance; if the wire is too thick, the axial heat conduction is fast, and the thermal relay may lag behind. The connecting wire at the output end of the thermal relay is generally a copper core wire. If an aluminum core wire is used, the cross-sectional area of the wire should be increased by 1.8 times, and the end of the wire should be tinned. Reference table for selection of cross-section of connecting wire:Setting current of thermal relay I / ACross-sectional area of connecting wire MM20 < IN ≤81.08 < IN ≤121.512 < IN ≤202.520 < IN ≤254.025 < IN ≤326.032 < IN ≤5010.050 < IN ≤6516.065 < IN ≤8525.085 < IN ≤11535.0115 < IN ≤15050.0150 < IN ≤16070.03.3 Use EnvironmentThis mainly refers to the ambient temperature, which has a greater impact on the speed of the thermal relay. The temperature of the medium surrounding the thermal relay should be the same as the temperature of the medium surrounding the motor, otherwise, the adjusted fit will be destroyed. For example: when the motor is installed in an environment of high temperature and the thermal relay is installed in an environment of lower temperature, the action of the thermal relay will lag (or the action current is large); otherwise, its action will be advanced (or the action current is small). For thermal relays without temperature compensation, they should be used at the place where there is little difference in an ambient temperature between the thermal relay and the motor. For the thermal relay with temperature compensation, it can be used in the place where the environmental temperature of the thermal relay and the motor is different, but the influence caused by the environmental temperature change should be minimized as much as possible. The ambient temperature of the thermal relay and the protected motor should be considered. When the ambient temperature of the thermal relay is lower than the ambient temperature of the protected motor by 15℃, a thermal relay with a larger rated current rating should be used; when the ambient temperature of the thermal relay is lower than the ambient temperature of the protected motor by 15℃, a thermal relay with a smaller rated current rating should be used. In addition, the load of the motor and the adjustment range that the thermal relay may require should also be considered.3.4 Adjustment of Thermal RelayBefore putting it into use, the setting current of the thermal relay must be adjusted to ensure that the set current of the thermal relay matches the rated current of the protected motor. Before the thermal relay is used in the circuit, the specific current of the thermal relay must be adjusted according to the rated current of the motor to meet the requirements of corresponding occasions. For example, for a 10kW, 380V motor with a rated current of 19.9A, a XX20-25 thermal relay can be used. The setting current of the thermal element is 17 ～ 21 ～ 25A. First, set it at 21A according to the general situation. If it is found that it often moves in advance and the temperature rise of the motor is not high, you can change the setting current to 25A and continue to observe; if the motor temperature rises at 21A, and the thermal relay lags, you can change the setting current to 17A and observe to get the best fit. It is used to adjust the rated current when overload protection of the motor is repeatedly operated for a short time. Multiple tests and adjustments in the field can get more reliable protection. The method is: first adjust the rated current of the thermal relay to be slightly smaller than the rated current of the motor. If it is found that it often moves during operation, then gradually increase the rated value of the thermal relay until it meets the operating requirements. There should be motor protection during the special operations. Motors with forward, reverse, and frequent on-off operations should not be protected by thermal relays. The ideal method is to protect it with a temperature relay or thermistor embedded in the winding.  Ⅳ Frequently Asked Questions about Thermal Relay1. What is a thermal relay?A relay that opens or closes contacts with a bending mechanism as a result of the difference in the expansion coefficients of a bimetal, which is heated by the current. ... The thermal relay is combined with a magnetic contactor because it cannot switch the main circuit by itself. The operating point can be changed. 2. How does a thermal relay work?A thermal relay works depending upon the above-mentioned property of metals. The basic working principle of thermal relay is that, when a bimetallic strip is heated up by a heating coil carrying overcurrent of the system, it bends and makes normally open contacts. 3. What is the purpose of thermal overload relay?Thermal overload relays are economic electromechanical protection devices for the main circuit. They offer reliable protection for motors in the event of overload or phase failure. The thermal overload relay can make up a compact starting solution together with contactors. 4. What are the two types of thermal overload relays?Thermal Overload RelaysThermal overloads can be divided into two types: solder melting type, or solder pot, and bimetal strip type. Because thermal overload relays operate on the principle of heat, they are sensitive to ambient (surrounding air) temperature. 5. How do you use a thermal overload relay?Overload relays protect a motor by sensing the current going to the motor. Many of these use small heaters, often bi-metallic elements that bend when warmed by the current to the motor. When the current is too high for too long, heaters open the relay contacts carrying current to the coil of the contactor. 6. How do you test a thermal overload relay?CEP7 Overload Relay test procedures:Measure the normal motor running current (i motor).Turn off the motor and let it cool for about 10 minutes.Calculate the following ratio: i (motor) / i (overload min FLA).Set the overload to its minimum FLA and turn on the motor.Wait for the overload to trip. 7. What is thermal overload relay how it functions?The function of a thermal overload relay, used in motor starter circuits is to prevent the motor from drawing excessive current which is harmful to motor insulation. It is connected either directly to motor lines or indirectly through current transformers. 8. What is the purpose of a thermal overload?Thermal overload relays are protective devices. They are designed to cut power if the motor draws too much current for an extended period of time. To accomplish this, thermal overload relays contain a normally closed (NC) relay. 9. What does a thermal overload relay consist of?Bimetallic thermal overload relays (sometimes referred to as heater elements) are made of two metals, with different coefficients of thermal expansion, that is fastened or bonded together. A winding, wrapped around or placed near the bimetallic strip, carries current. 10. How do I know if my overload relay is bad?Unplug the start relay from the compressor and give it a shake. If you can hear rattling on the inside of the start relay, then the part is bad and will have to be replaced. If it's not rattling and appears to be in good condition, you may have a problem with the actual compressor. 

IntroductionA three-phase circuit consists of a three-phase source, a three-phase load, and a three-phase transmission line. The most basic characteristic of this circuit is that it has one or more groups of power supplies. Each group consists of three sinusoidal power supplies with the same amplitude, the same frequency, 120° phase difference, and the power supply and the load are connected in a specific way. Three-phase circuits are widely used in power systems such as power generation, transmission, distribution, and high-power electrical equipment.What does 3 phase mean?CatalogIntroductionⅠ Three-phase Circuit Basics1.1 Three-phase Circuit Characterized1.2 Three-phase Circuit Terms1.3 Three-phase Voltage & Current1.4 Three-phase Circuit AdvantagesⅡ Symmetrical vs Asymmetrical2.1 Symmetrical Three-phase Circuit2.2 Three-phase AsymmetryⅢ Power in Three Phase Circuit FormulasⅣ Frequently Asked Questions about Three-phase CircuitⅠ Three-phase Circuit BasicsThe three phases could be supplied over six wires, with two wires reserved for the exclusive use of each phase. However, they are generally supplied over only three wires, and the phase or line voltages are the voltages between the three possible pairs of wires. The phase or line currents are the currents in each wire. Voltages and currents are usually expressed as rms or effective values, as in single-phase analysis.1.1 Three-phase Circuit CharacterizedSpecial power supplySpecial loadSpecial connectionSpecial solution1.2 Three-phase Circuit Terms1) End wire (fire wire)2) Neutral line3) Line current4) Line voltage5) Phase current6) Phase voltage7) Three-phase three-wire system and three-phase four-wire system1.3 Three-phase Voltage & CurrentStar ConnectionSummery: Line Voltage vs Phase Voltage1) The line current is equal to the corresponding phase current.2) If the phase voltage is symmetrical, the line voltage is also symmetrical.3) The line voltage is equal to √3 times the phase voltage.4) The phase of the line voltage leads the corresponding phase voltage by 30°. Delta ConnectionSummery: Line Current vs Phase Current1) The line voltage is equal to the corresponding phase voltage.2) If the phase currents are symmetrical, the line currents are also symmetrical.3) The line current is equal to √3 times the phase voltage.4) The phase of the line current lags behind the corresponding phase voltage by 30°.1.4 Three-phase Circuit AdvantagesPower generation: Three-phase power is increased by 50% compared to single-phase power.Transmission: 25% less material than single-phase circuit transmission. That is, under certain conditions, transmitting a certain amount of power by three-phase only requires 75% of the copper of single-phase transmission.Power distribution: More economical than single-phase transformers and easier to connect to the load.Transportation: simple structure, low cost, reliable operation, convenient maintenance.In addition, three wires are usually seen in high-voltage transmission lines, whether on towers or poles, with pin or suspension insulators. Some high-voltage lines are now DC, since solid state devices make it easier to convert to and from AC. The DC lines are free of the problems created by phase, as well as eliminating the skin effect that reduces the effective area of the conductors. It is not nearly as easy to manage long-distance electrical transmission as might be thought.Ⅱ Symmetrical vs Asymmetrical2.1 Symmetrical Three-phase CircuitA symmetrical three-phase power source is usually generated by a three-phase synchronous generator, as shown in Figure (a). Among them, the three-phase windings differ by 120° in space. When the rotor rotates at a uniform angular velocity ω, an induced voltage is generated in the three-phase winding, thereby forming a symmetrical three-phase power supply as shown in Figure (b). Among them, the three ends of A, B, and C are called the start end, and the three ends of X, Y, and Z are called the end. When you connect a load to the three wires, it should be done in such a way that it does not destroy the symmetry.Instantaneous Voltage Calculation of Three-phase PowerIn the formula, take the phase A voltage uA as the reference sine quantity. The three-phase voltage waveform diagram is shown in Figure (a).The key to understanding three-phase is to understand the phasor diagram for the voltages or currents. The phasor of the three-phase power supply can be represented by the Figure (b).The characteristics of the symmetrical three-phase power supply can be derived from the above formula:From the above formula, the sum of the instantaneous value of the three-phase power supply and the sum of the phasor are always zero.The sequence in which each phase of the three-phase power passes through the same value (such as the maximum value) is called the phase sequence of the three-phase power, and the phase sequence of the above-mentioned three-phase voltage is called the positive sequence. Conversely, if phase B exceeds 120° of phase A and phase C exceeds 120° of phase B, this phase sequence is called reverse sequence. If there is no special instructions, it will generally default to positive order.2.2 Three-phase Asymmetry1) In a three-phase circuit, as long as there is asymmetrical part, it is called a three-phase asymmetry.2) The complex power absorbed by the three-phase load is equal to the sum of various complex powers.3) The instantaneous power of a three-phase circuit is the sum of the instantaneous power of each phase load.4) In a three-phase three-wire circuit, whether symmetrical or not, two power meters can be used to measure three-phase power.When the power supply voltage in the three-phase circuit is asymmetrical or the parameters in the circuit are asymmetrical, the current in the circuit is generally asymmetrical. This kind of circuit is called three-phase asymmetry. There are a lot of asymmetry parts in three-phase circuits, and the causes are different. For example, there are many low-power single-phase loads in a three-phase circuit, it is difficult to make them into a completely symmetrical circuit. When a three-phase circuit is broken or short-circuited, it is also a three-phase asymmetry circuit. In addition, some electrical equipment and instruments formally use three-phase asymmetry to work.For example, the most common low-voltage three-phase four-wire system. Due to the large number of single-phase loads in the low-voltage system, the equivalent impedances ZA, ZB, and ZC of the three phases circuit are generally different from each other, and the power supply voltage can generally be considered symmetrical. In this way, a symmetrical three-phase power supply converts to an asymmetrical three-phase load.The circuit shown in the figure has two nodes, and the voltage between the two nodes can be directly calculated according to the node voltage method.Although the power supply voltage in the above formula is symmetrical, the voltage between the neutral point of the power supply and the neutral point of load is not zero due to the load asymmetry, that is, UNN≠0. According to Kirchhoff's voltage law, the phase voltage of the load can be obtained as:The phasor diagram of each voltage corresponding to the above formula is as follows:Ⅲ Power in Three Phase Circuit Formulas1. Average PowerSuppose the power absorbed by a phase load in a symmetrical three-phase circuit is equal to Pp=UpIpcosφ, where Up is the phase voltage and Ip is the phase current of the load. Then the total three-phase power is: P=3UpIpcosφPay Attention To1) φ in the above formula is the phase difference angle (impedance angle) of phase voltage and phase current.2) cosφ is the power factor of each phase, in a symmetrical three-phase system:cosφA=cosφB=cosφC=cosφ3) The formula calculates the circuit power (or the power absorbed by the load).When the load is in a star connection, the line voltage  and line current  at the load end are substituted into the above formula:When the load is in a delta connection, the line voltage  and line current  at the load end are substituted into the above formula:2. Reactive powerThe reactive power absorbed by the load in a symmetrical three-phase circuit is equal to the sum of the reactive power of each phase:3. Apparent Power4. Instantaneous PowerSuppose the voltage and current of phase A of the three-phase load are:Then the instantaneous power of each phase is:It can be proved that their sum isThe above formula shows that the instantaneous power of a symmetrical three-phase circuit is a constant, and is equal to the average power. This is one of the advantages of a symmetrical circuit. For example, on a three-phase motor, a balanced electromagnetic torque is obtained and mechanical vibration is avoided, which is not available in single-phase motors. Ⅳ Frequently Asked Questions about Three-phase Circuit1. What is a 3 phase circuit?Three-phase power is a three-wire ac power circuit with each phase ac signal 120 electrical degrees apart. ... three-phase is that a three-phase power supply better accommodates higher loads. Single-phase power supplies are most commonly used when typical loads are lighting or heating, rather than large electric motors. 2. How many wires are in a 3 phase?four wiresThe three-phase system has four wires. Three are conductors and one is neutral. 3. What is the 3 phase power formula?3-Phase Calculations. For 3-phase systems, we use the following equation: kW = (V × I × PF × 1.732) ÷ 1,000. 4. What is the advantage of three-phase system?A three-phase circuit provides greater power density than a one-phase circuit at the same amperage, keeping wiring size and costs lower. In addition, three-phase power makes it easier to balance loads, minimizing harmonic currents and the need for large neutral wires. 5. What is meant by 3 phase balanced load?A balanced three-phase voltage or current is one in which the size of each phase is the same, and the phase angles of the three phases differ from each other by 120 degrees. ... With such a balanced load, if a balanced three-phase supply is applied, the currents will also be balanced.