Solution for Harsh Environment Protection and Long Service Life Low-Voltage Current Transformers

​1. Problem Focus: Challenges in Harsh Operating Conditions​
In industrial automation, outdoor power facilities, shipboard power systems, and special operating environments, current transformers (CTs) are constantly exposed to harsh factors like high temperature, high humidity, dust, salt spray, oil contamination, and vibration. This poses severe challenges to equipment protection capabilities and long-term reliability. Traditional CTs are prone to insulation aging, component failure, accuracy degradation, and even safety incidents due to environmental degradation.

​2. Core Solution: Comprehensive Protection and Robust Design​
​2.1 Fully Encapsulated Integrated Structure Design​

• ​Casing Material:​​ Utilizes high-strength engineering plastics (PPS or PBT) or die-cast aluminum housing with surface anti-corrosion treatment (anodizing/epoxy coating).
• Engineering Plastics: Offer high mechanical strength, chemical resistance (acid, alkali, oil), flame retardancy, and dimensional stability.
• Die-Cast Aluminum + Anti-Corrosion: Provides exceptional mechanical protection and heat dissipation capacity. Surface treatment effectively resists salt spray and humid environment corrosion.
  ​2.2 High-Level Seal Protection at Interfaces​
• ​Potting Process:​​ Wiring terminals and housing interfaces are rigorously sealed using IP67/IP68-rated waterproof sealant.
• Ensures zero ingress of water, dust, or contaminants during continuous immersion, high-pressure water washing, or prolonged high-humidity environments, protecting internal electrical connections.
  ​2.3 Enhanced Protection for Internal Electronic Components​
• ​Conformal Coating:​​ High-reliability conformal coating is applied to internal PCBs and critical electronic components (e.g., signal conditioning circuits, ADC chips).
• Effectively forms a protective film to resist moisture, condensation, salt spray, mold, and harmful gas corrosion, preventing circuit corrosion and short circuits.
  ​2.4 Wide-Temperature Range, Long-Lifetime Component Selection​
• ​Component Grade:​​ All core components (resistors, capacitors, ICs, magnetic materials) are selected from industrial-grade (-40°C ~ +85°C) or automotive-grade (AEC-Q certified) products.
• Ensures stable performance under extreme high/low temperatures and severe thermal shock. Failure rates are significantly lower than commercial-grade components, extending overall lifespan.
  ​2.5 Vibration-Resistant Structural Optimization​
• Effectively absorbs and dissipates mechanical vibration and shock energy through rational internal layout, anti-vibration damping design (e.g., flexible mounting, shock-absorbing washers), and housing rigidity. Prevents internal connection loosening or component damage, meeting stringent vibration standards (e.g., IEC 60068-2-6).

​3. Core Advantages​

• ​Exceptional Environmental Endurance:​​ Operates stably in environments with high temperature (up to 85°C), high humidity (≥95% RH), dust, salt spray (complies with IEC 60068-2-11), oil contamination, industrial chemical gases, and strong vibration.
• ​Ultra-High Protection Level:​​ Overall protection level reaches IP67 (dust-tight and protected against water immersion) or IP68 (continuous underwater protection), far exceeding requirements for conventional industrial equipment.
• ​Significantly Extended Service Life:​​ Through anti-corrosion materials, sealing against moisture, long-lifetime component selection, and vibration-resistant design, the Mean Time Between Failures (MTBF) is substantially improved. Design life is extended by over 50% compared to standard products.
• ​Optimized Lifecycle Cost:​​ Reduces failures, downtime, maintenance frequency, and replacement costs caused by environmental factors, significantly lowering overall operation and maintenance expenses.

​4. Typical Application Scenarios​

• ​Heavy Industrial Environments:​​ Steel mills, chemical plants, cement plants, mining equipment (dust, high temperature, corrosive gases, vibration).
• ​Outdoor Power Facilities:​​ Wind/solar farm combiner boxes, outdoor distribution cabinets (sun/rain exposure, severe temperature fluctuations, condensation).
• ​Shipboard & Offshore Platforms:​​ Shipboard power distribution systems, offshore wind platforms (high humidity, salt spray, mold, vibration/shock).
• ​Rail Transportation:​​ Locomotive traction, onboard power distribution systems (strong vibration, wide temperature range, oil contamination).
• ​Special Equipment:​​ Construction machinery, agricultural machinery (oil contamination, mud, severe vibration).