A manufacturing method of the flexible copper sensor for protection of hydro generators and transformers

Abstract

Protection of hydro generators and transformers is very important for managing of the power station. In this paper, we present the low-cost copper thick film flexible sensor for measuring the temperature in the stator of hydro generators and iron core of transformers. This sensor is based on PCB (printed circuit board) technology. A new design is proposed to avoid the defects on the resistive lead of the sensors. The detour leads are added in the resistive lead layout of the sensor. There were the improvements of the actual extract rate of sensor in the fabrication process and the accuracy of initial resistance of the sensor (the resistance at 0 °C). The actual extract rate is 100% in the sensor fabrication process by handling and deviations of the initial resistances (R0=100Ω) are less than 0.1Ω in the fabricated sensors.