Magnetic current sensor integration into high current connector device with mounting for torque stabilization

A power connector configured to conduct a current, the power connector comprising:

• a conductive frame comprising a base structure, an extension structure, and a connector head structure that define a current path for the current,
• wherein the base structure is configured to be coupled to at least one primary conductor for receiving the current from the at least one primary conductor,
• wherein the connector head structure is arranged relative to the base structure, wherein the connector head structure is configured to be mechanically coupled to an electrical interface of a device to be supplied with the current, and wherein the connector head structure is configured to receive the current from the base structure and output the current from the power connector to the electrical interface of the device,
• wherein the extension structure is coupled to and vertically extends between the base structure and the connector head structure, wherein the extension structure is configured to receive the current from the base structure and deliver the current to the connector head structure,
• wherein the extension structure includes a current constriction region coupled between two current non-constriction regions, wherein the current constriction region is configured to increase a magnetic flux density of a magnetic field produced by the current flowing through the current constriction region relative to magnetic flux densities of the magnetic field produced by the current flowing through the two current non-constriction regions,
• wherein the connector head structure includes a bore-hole that vertically extends into the connector head structure toward the base structure, wherein the bore-hole is configured to receive a fastener for coupling the power connector to the electrical interface of the device, and
• wherein the connector head structure has a mechanical engagement feature configured to mechanically engage with a torque stabilization tool during a fastening of the fastener to the connector head structure in order to prevent a torque applied by the fastening of the fastener from being transferred to the extension structure.

A method of assembly of a power connector for delivery of a current from a current source to a load device, wherein the power connector includes a conductive frame comprising a base structure, an extension structure, and a connector head structure that define a current path for the current, wherein the extension structure is coupled to and vertically extends between the base structure and the connector head structure, wherein the extension structure is configured to receive the current from the base structure and deliver the current to the connector head structure, wherein the connector head structure includes a bore-hole that vertically extends into the connector head structure toward the base structure, wherein the bore-hole is configured to receive a fastener for coupling the power connector to an electrical interface of the load device, and wherein the connector head structure has a mechanical engagement feature configured to mechanically engage with a torque stabilization tool during a fastening of the fastener to the connector head structure in order to prevent a torque applied by the fastening of the fastener from being transferred to the extension structure, the method comprising:

• coupling the base structure to at least one primary conductor for receiving the current from the at least one primary conductor;
• coupling a magnetic current sensor to a sensor area of the extension structure, wherein the sensor area includes a current constriction region coupled between two current non-constriction regions;
• inserting the fastener through a through-hole of a cable shoe, wherein the cable shoe is mechanically and electrically coupled to the electrical interface of the load device;
• inserting the fastener into the bore-hole;
• mechanically engaging the torque stabilization tool with the mechanical engagement feature to stabilize the connector head structure;
• and
• applying, with a fastening tool, the torque to the fastener to fasten the cable shoe to the connector head structure.