Manganese-copper shunt assembly and smart meter

Abstract

The application discloses a manganese-copper shunt assembly and a smart electric meter, and belongs to the technical field of electric power measurement. The smart electric meter comprises the manganese-copper shunt assembly. In particular, the manganese-copper shunt assembly comprises a shunt unit, a fixing unit and a sensing unit. The shunt unit comprises a first shunt and a second shunt, both of which have a conductive main body, a current sampling structure and conductive connecting parts at two ends, and the conductive connecting parts are provided with mounting positioning structures. The second shunt is arranged in the middle region of the first shunt and is connected in series in the firewire and zero line loop respectively, so as to simultaneously measure the current and detect the electric leakage by comparing the current values. The sensing unit is electrically connected with the second shunt. The application optimizes the structure layout, improves the current measurement accuracy and the electric leakage detection reliability, has good heat dissipation performance and mounting stability, is suitable for devices such as the smart electric meter, and can effectively guarantee the electric safety.

Description

Technical Field

[0001] This invention belongs to the field of power measurement technology, specifically referring to a manganese copper shunt assembly and a smart meter. Background Technology

[0002] In power systems, electricity meters are crucial devices for measuring electrical energy consumption, and shunts, as key components of electricity meters, convert large currents into small voltage signals to facilitate metering. With the development of the power industry, increasingly higher demands are being placed on the measurement accuracy, safety, and reliability of electricity meters.

[0003] Traditional electricity meters typically use a single shunt for current measurement. However, a single shunt can only measure the current of one phase. While this design achieves basic current measurement, it has a critical flaw: in a normal electrical circuit, the live wire current and the neutral wire current should theoretically be exactly equal. If there is a leakage in the circuit, the live wire current will be greater than the neutral wire current. Since a single shunt cannot simultaneously acquire the current data of both the live and neutral wires, it cannot determine whether there is a leakage by comparing the difference between the two. This results in the meter lacking leakage detection capability and failing to meet the needs of electrical safety monitoring. Summary of the Invention

[0004] In view of the above situation and to overcome the defects of the prior art, the purpose of the present invention is to provide a manganese copper shunt assembly to at least partially solve the problems mentioned in the background art.

[0005] The technical solution adopted by the present invention is as follows: On the one hand, a manganese copper shunt assembly is proposed, including a shunt unit, a fixing unit and a sensing unit. The shunt unit includes a conductive body, a current sampling structure and two conductive connection parts. The conductive connection parts are disposed at both ends of the conductive body, and the conductive connection parts are provided with a mounting and positioning structure.

[0006] The fixing unit includes an insulating substrate, on which are provided a receiving portion adapted to the conductive connection portion, a heat dissipation structure, a through structure corresponding to the mounting and positioning structure, and an overall positioning structure;

[0007] The current splitting unit includes a first current splitter and a second current splitter. The second current splitter is disposed in the middle region of the first current splitter. The first current splitter and the second current splitter are configured to be connected in series in the live wire and neutral wire circuits, respectively. The sensing unit is electrically connected to the second current splitter.

[0008] Furthermore, the conductive body of the first shunt is a first conductive sheet, the current sampling structure of the first shunt is a sampling point set on the first conductive sheet, the conductive connection part of the first shunt is a first conductive post, and the mounting and positioning structure of the first shunt is a first mounting hole.

[0009] Furthermore, the conductive body of the second shunt is a second conductive sheet, which passes through the sensing unit. The current sampling structure of the second shunt is a sampling line connected to the second conductive sheet. The conductive connection part of the second shunt is a second conductive post. The mounting and positioning structure of the second shunt is a second mounting hole.

[0010] Furthermore, the sampling points are multiple metal contacts disposed on the first conductive sheet, the distance between two adjacent metal contacts is 5-15mm, the diameter of the metal contacts is 1-3mm, and the height of the metal contacts is 0.1-0.3mm.

[0011] Furthermore, the conductive connection part is made of brass, and the conductive connection part consists of a first conductive post and a second conductive post. The diameter of the first conductive post and the second conductive post is 5-10 mm, and the length is 10-20 mm.

[0012] The mounting and positioning structure is a mounting hole with a diameter of 2-4mm and a depth of 5-15mm, and the mounting hole is provided with an internal thread.

[0013] Furthermore, the insulating substrate is an insulating shell, and the receiving part is a mounting groove, of which there are four. The four mounting grooves are respectively provided for the conductive connection part. The depth of the mounting groove is 5-15mm, and the inner diameter of the mounting groove is 0.1-0.3mm larger than the diameter of the conductive connection part.

[0014] Furthermore, the heat dissipation structure consists of heat dissipation fins corresponding to the mounting slot, the number of heat dissipation fins is 5-15, the height of the heat dissipation fins is 3-8mm, the spacing between the heat dissipation fins is 1-3mm, and the thickness of the heat dissipation fins is 0.5-1.5mm.

[0015] The through structure consists of four clearance holes, the diameter of which is 0.5-1mm larger than the diameter of the mounting and positioning structure; the overall positioning structure consists of positioning holes located in the middle of the insulating shell.

[0016] Furthermore, the sensing device is a current transformer, and the inner diameter of the current transformer is the same as the width of the conductive body.

[0017] A second aspect of the present invention provides a smart meter, including a manganese copper shunt assembly, wherein a first shunt and a second shunt of the manganese copper shunt assembly are respectively connected in series in the live wire and neutral wire circuit of the smart meter, for simultaneously measuring the current of the live wire and the neutral wire, and detecting leakage current in the circuit by comparing the current values ​​of the two.

[0018] Beneficial effects:

[0019] Smart meters utilize a manganese-copper shunt assembly, connecting the first and second shunts in series to the live and neutral wire circuits, respectively. By simultaneously measuring and comparing the current values ​​of the live and neutral wires in real time, leakage current in the circuit can be detected. When the difference between the two exceeds a set threshold, a leakage fault is identified, and the meter will issue a corresponding alarm signal, thereby reducing potential electrical safety hazards.

[0020] The measurement results of the second shunt are verified by the sensing unit, which further improves the measurement accuracy. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of a manganese-copper shunt assembly structure according to an embodiment of the present invention;

[0022] Figure 2 This is a top view schematic diagram of a manganese-copper shunt assembly according to an embodiment of the present invention;

[0023] Figure 3 This is an exploded structural diagram of a manganese-copper shunt assembly according to an embodiment of the present invention;

[0024] Figure 4 This is a schematic diagram of the insulating substrate structure in a manganese-copper shunt assembly according to an embodiment of the present invention;

[0025] Figure 5 This is a schematic diagram of the first shunt structure of a manganese-copper shunt assembly according to an embodiment of the present invention;

[0026] Figure 6 This is a schematic diagram of the second splitter structure of a manganese-copper splitter assembly proposed in an embodiment of the present invention.

[0027] Among them, 1. First shunt; 11. First conductive sheet; 12. Sampling point; 13. First conductive post; 14. First mounting hole; 2. Second shunt; 21. Second conductive sheet; 22. Sampling line; 23. Second conductive post; 24. Second mounting hole; 3. Insulating substrate; 31. Insulating shell; 32. Mounting groove; 33. Heat dissipation fins; 34. Clearance hole; 35. Positioning hole; 4. Current transformer.

[0028] The accompanying drawings are provided to further understand the embodiments and form part of the specification. They are used together with the embodiments for explanation and do not constitute a limitation on the embodiments. Detailed Implementation

[0029] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection.

[0030] In the description of the embodiments, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments.

[0031] like Figures 1-6 As shown, in some embodiments, a manganese-copper shunt assembly comprises three main functional modules: a shunt unit, a fixed support unit, and a signal sensing unit. The shunt unit includes at least two independent shunt units, each consisting of a conductive body, a current sampling structure, and conductive connecting parts. The conductive body is cast from a specially formulated manganese-copper alloy, exhibiting excellent conductivity and stable temperature characteristics. The two conductive connecting parts are welded and fixed to both ends of the conductive body.

[0032] The fixing unit is composed of an insulating substrate 3, which has a receiving part that matches the shape of the conductive connection part. The bottom surface of the substrate also adopts an integrated heat dissipation structure composed of arrayed heat dissipation fins 33. At the same time, a through threaded fixing hole is provided at the position corresponding to the installation and positioning structure of the conductive connection part.

[0033] In practical implementation, the shunt unit comprises two independent parts: a first shunt 1 and a second shunt 2. The second shunt 2 is located in the middle region of the first shunt 1, and the two are kept at an insulated distance. Specifically, the first shunt 1 and the second shunt 2 are connected in series to the live wire circuit and the neutral wire circuit, respectively. By synchronously measuring the current values ​​of the live wire and the neutral wire and performing digital real-time comparison, leakage current in the circuit can be accurately detected.

[0034] It should be noted that the second shunt 2 is located in the middle area of ​​the first shunt 1, and a reasonable distance is maintained between the two and between the shunt 2 and the inner wall of the insulating housing 3, which reduces electromagnetic interference; the current sampling structure is reasonably designed, the sampling signal is stable, and it is less affected by external interference.

[0035] The connection between the sensing unit and the second shunt 2 includes a built-in signal amplification circuit and an AD conversion module for acquiring and processing current signals and outputting standardized detection signals. Verification of the measurement results via the sensing unit further improves measurement accuracy.

[0036] In the operation of the manganese-copper shunt assembly of the present invention, the first shunt 1 is connected in series in the live wire circuit, and the second shunt 2 is connected in series in the neutral wire circuit. When current flows through the first shunt 1 and the second shunt 2, a voltage drop proportional to the current is generated on them. The voltage drop signals on the first shunt 1 and the second shunt 2 are sampled and acquired respectively, and these signals are transmitted to the main control chip.

[0037] The main control chip processes and calculates the two voltage drop signals to obtain the current values ​​of the live wire and the neutral wire. By comparing these two current values, leakage in the circuit can be detected: when the difference between the two exceeds a set threshold, it is determined that there is a leakage fault, and the meter will issue a corresponding alarm signal.

[0038] like Figure 1 and Figure 5 As shown, in some embodiments, the conductive body of the first shunt 1 is a first conductive sheet 11, which is made of high-purity manganese copper alloy. This material has an extremely low temperature coefficient, which can effectively reduce the influence of temperature changes on the resistance value and ensure the stability of measurement accuracy.

[0039] The current sampling structure of the first shunt 1 is a sampling point 12 set on the first conductive sheet 11. The sampling point 12 is made of copper alloy and is fixed to the first conductive sheet 11 by welding, forming a good electrical connection with the first conductive sheet 11. The sampling point 12 is used to collect the voltage drop signal on the first conductive sheet 11, providing a basic signal for current measurement.

[0040] The first conductive sheet 11 has first conductive posts 13 at both ends, which serve as conductive connections. These posts are made of brass, which has good conductivity and mechanical strength, ensuring stable current transmission and structural robustness. The first conductive posts 13 have a diameter of 5-10 mm and a length of 10-20 mm. They are fixedly connected to both ends of the first conductive sheet 11 by welding, ensuring welding strength and conductivity.

[0041] A first mounting hole 14, serving as a mounting and positioning structure, is provided on the first conductive post 13. The diameter of the first mounting hole 14 is 2-4 mm, and the hole is provided with internal threads. The first mounting hole 14 is used to fix the first shunt 1 to the fixing member 3, ensuring the installation stability of the first shunt 1.

[0042] like Figure 1 and Figure 6 As shown, in some embodiments, the structure of the second shunt 2 is the same as that of the first shunt 1. Specifically, the conductive body of the second shunt 2 is the second conductive sheet 21, which is also made of high-purity manganese copper alloy. Its thickness and width are the same as those of the first conductive sheet 11 to ensure that it has the same electrical performance as the first shunt 1, which facilitates subsequent current comparison and leakage monitoring.

[0043] The second conductive sheet 21 passes through the sensing unit, and the current transformer 4 can sense the current change on the second conductive sheet 21 and generate an induction signal, which is used to verify and assist in the measurement of the current measured by the second shunt 2, thereby improving the measurement accuracy.

[0044] A sampling line 22, serving as a current sampling structure, is connected to the second conductive sheet 21. The sampling line 22 is a copper-core insulated wire. One end of the sampling line 22 is connected to the second conductive sheet 21 by soldering, and the other end is provided with a terminal block for easy connection to an external measurement circuit. The sampling line 22 is used to transmit the voltage drop signal on the second conductive sheet 21 to the measurement circuit.

[0045] The two ends of the second conductive sheet 21 are connected to the second conductive post 23, which serves as a conductive connection part. The material, size and connection method of the second conductive post 23 are the same as those of the first conductive post 13, to ensure the electrical performance consistency with the first shunt 1.

[0046] The second conductive post 23 is provided with a second mounting hole 24 as a mounting and positioning structure. The size and structure of the second mounting hole 24 are the same as those of the first mounting hole 14, and it is used to fix the second shunt 2 to the fixing member 3.

[0047] like Figure 5 As shown, in some embodiments, sampling points 12 are multiple metal contacts disposed on the first conductive sheet 11. These metal contacts are evenly distributed, with a distance of 5-15mm between two adjacent metal contacts, a diameter of 1-3mm, and a height of 0.1-0.3mm. These metal contacts are connected to an external measuring circuit through a copper core insulated wire to ensure that the voltage drop signal on the first conductive sheet 11 is transmitted to the measuring circuit.

[0048] like Figure 5 and Figure 6As shown, in some embodiments, the conductive connections are all made of brass to ensure consistent electrical performance. Specifically, the conductive connections are the first conductive post 13 and the second conductive post 23, with a diameter in the range of 5-10 mm, preferably 6-8 mm. This size range takes into account both conductivity requirements and mechanical strength requirements to ensure sufficient conductive cross-sectional area. The length has been controlled between 10-20 mm after multiple experiments, with a typical value of 15 mm. This length design ensures good conductivity, meets spatial layout requirements, and facilitates installation and maintenance.

[0049] The mounting and positioning structure consists of mounting holes with a diameter of 2-4mm, ideally 3mm. These holes are internally threaded to ensure a reliable threaded connection with the matching bolts. This design not only ensures the stability of the component installation but also guarantees the reliability of the conductive connection, while facilitating subsequent disassembly and maintenance. The entire conductive connection design fully considers factors such as conductivity, mechanical strength, and ease of installation.

[0050] like Figures 1-4 As shown, in some embodiments, the insulating substrate 3 is an insulating shell 31, which is made of fiberglass material. This material has good insulation performance, heat resistance, and mechanical strength, and can meet the requirements of the internal operating environment of the meter. The insulating shell 31 is provided with four mounting grooves 32 as receiving parts, corresponding to the two first conductive posts 13 of the first shunt 1 and the two second conductive posts 23 of the second shunt 2, respectively. The depth of the mounting groove 32 is in the range of 5-15mm, preferably 10mm, and the inner diameter is 0.1-0.3mm larger than the diameter of the first conductive post 13 and the second conductive post 23, preferably 0.2mm. This precise tolerance design ensures smooth insertion of the conductive connection part and a tight fit between them, preventing loosening.

[0051] Furthermore, in some embodiments, the insulating housing 31 is also provided with heat dissipation fins 33 as a heat dissipation structure. The heat dissipation fins 33 are correspondingly arranged with the mounting slots 32, and the number is 5-15, preferably 10. The height of the heat dissipation fins 33 is 3-8mm, preferably 5mm, the spacing between them is 1-3mm, preferably 2mm, and the thickness is 0.5-1.5mm, preferably 1mm. The heat dissipation fins 33 are integrally formed with the insulating housing 31, which can effectively increase the heat dissipation area, improve the heat dissipation efficiency, and dissipate the heat generated when the shunt is working in a timely manner, avoiding the resistance value drift caused by excessive temperature, and ensuring the long-term working stability of the component.

[0052] The insulating housing 31 is provided with four clearance holes 34 as through structures, which are respectively provided with the first mounting hole 14 and the second mounting hole 24. This facilitates the screws to pass through the clearance holes 34 to fix the conductive post in the mounting groove 32.

[0053] The insulating housing 31 is also provided with a positioning hole 35 as an integral positioning structure. The positioning hole 35 is located in the middle of the insulating housing 31 and is used to fix the entire manganese copper shunt assembly inside the meter housing to ensure that the assembly is installed in the meter accurately and firmly.

[0054] like Figures 1-3 As shown, in some embodiments, the sensing device used in this component is a current transformer 4. Specifically, the current transformer 4 is a current transformer 4 specifically designed for current measurement. In terms of structural design, the inner diameter of the current transformer 4 is precisely calculated to be completely consistent with the width of the conductive body. This equal-size design ensures the accuracy and stability of current measurement.

[0055] During assembly of the manganese-copper shunt assembly of the present invention, the second conductive sheet 21 is first passed through the central hole of the current transformer 4. Then, the two second conductive posts 23 of the second shunt 2 are placed into the two middle mounting slots 32. Finally, the two first conductive posts 13 of the first shunt 1 are placed into the remaining two mounting slots 32 on the insulating housing 31, ensuring that the second shunt 2 is located in the middle area of ​​the first shunt 1, and the distance between two adjacent first conductive posts 13 and second conductive posts 23 is 10mm. This layout design can effectively reduce electromagnetic interference between the two shunts and improve measurement accuracy.

[0056] Then, by passing screws through the clearance hole 34 and the mounting hole, the first shunt 1 and the second shunt 2 are securely fixed to the insulating housing 31. Finally, the entire assembly is fixed inside the meter housing through the positioning hole 35, and the sampling point 12, the sampling line 22, and the output terminal of the current transformer 4 are connected to the main control chip inside the meter.

[0057] Furthermore, in some embodiments, a smart meter includes the aforementioned manganese-copper shunt assembly, wherein: a first shunt 1 is connected in series in the live wire circuit of the smart meter for measuring the live wire current, and a second shunt 2 is connected in series in the neutral wire circuit of the smart meter for measuring the neutral wire current. The leakage current in the circuit is detected by comparing the current values ​​of the two shunts, and the leakage current alarm function of the meter is triggered.

[0058] The specific workflow of this invention is as follows: a first shunt 1 is connected in series in the live wire circuit, and a second shunt 2 is connected in series in the neutral wire circuit. When current flows through the first conductive plate 11 and the second conductive plate 21, a voltage drop proportional to the current is generated on them. Sampling point 12 collects the voltage drop signal on the first conductive plate 11, and sampling line 22 collects the voltage drop signal on the second conductive plate 21. These signals are transmitted to the main control chip of the smart meter.

[0059] The main control chip processes and calculates the two voltage drop signals to obtain the current values ​​of the live wire and the neutral wire. By comparing these two current values, leakage in the circuit can be detected: when the difference between the two exceeds a set threshold, a leakage fault is identified, and the smart meter will issue a corresponding alarm signal. Simultaneously, the current transformer 4 senses the current on the second conductive plate 21, and the generated induced signal can be used to verify the current measured by the second shunt 2, further improving measurement accuracy.

[0060] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0061] The embodiments have been described above, and such description is not restrictive. The figures shown are only one embodiment, and the actual structure is not limited to this. In short, if a person skilled in the art is inspired by this description and designs a similar structure and embodiment without departing from the inventive spirit, such design should fall within the scope of protection.

Claims

1. A manganese-copper shunt assembly, characterized in that, It includes a current shunting unit, a fixing unit and a sensing unit. The current shunting unit includes a first current shunting device (1) and a second current shunting device (2). Both the first current shunting device (1) and the second current shunting device (2) include a conductive body, a current sampling structure and a conductive connection part. The conductive connection part is disposed at both ends of the conductive body and is provided with an installation positioning structure. The fixing unit includes an insulating substrate (3), and the insulating substrate (3) is provided with a receiving part adapted to the conductive connection part, a heat dissipation structure, a through structure corresponding to the mounting and positioning structure, and an overall positioning structure. The second shunt (2) is disposed in the middle area of ​​the first shunt (1). The first shunt (1) and the second shunt (2) are configured to be connected in series in the live wire and neutral wire circuits, respectively. The sensing unit is electrically connected to the second shunt (2). The sensing unit is a current transformer (4), and the inner diameter of the current transformer (4) is the same as the width of the conductive body.

2. The manganese-copper shunt assembly according to claim 1, characterized in that, The conductive body of the first shunt (1) is the first conductive sheet (11), the current sampling structure of the first shunt (1) is the sampling point (12) set on the first conductive sheet (11), the conductive connection part of the first shunt (1) is the first conductive post (13), and the installation positioning structure of the first shunt (1) is the first mounting hole (14).

3. The manganese-copper shunt assembly according to claim 1, characterized in that, The conductive body of the second shunt (2) is the second conductive sheet (21), which passes through the sensing unit. The current sampling structure of the second shunt (2) is the sampling line (22) connected to the second conductive sheet (21). The conductive connection part of the second shunt (2) is the second conductive post (23). The mounting and positioning structure of the second shunt (2) is the second mounting hole (24).

4. The manganese-copper shunt assembly according to claim 2, characterized in that, The sampling point (12) is a plurality of metal contacts set on the first conductive sheet (11). The distance between two adjacent metal contacts is 5-15mm, the diameter of the metal contacts is 1-3mm, and the height of the metal contacts is 0.1-0.3mm.

5. The manganese-copper shunt assembly according to claim 1, characterized in that, The conductive connection part is made of brass. The conductive connection part is a first conductive post (13) and a second conductive post (23). The diameter of the first conductive post (13) and the second conductive post (23) is 5-10mm and the length is 10-20mm. The mounting and positioning structure is a mounting hole with a diameter of 2-4mm and an internal thread inside.

6. The manganese-copper shunt assembly according to claim 1, characterized in that, The insulating substrate (3) is an insulating shell (31), and the receiving part is a mounting groove (32), with a quantity of four. The four mounting grooves (32) are respectively provided for the conductive connection part. The depth of the mounting groove (32) is 5-15mm, and the inner diameter of the mounting groove (32) is 0.1-0.3mm larger than the diameter of the conductive connection part.

7. The manganese-copper shunt assembly according to claim 6, characterized in that, The heat dissipation structure is a heat dissipation fin (33) corresponding to the mounting slot (32). The number of heat dissipation fins (33) is 5-15, the height of the heat dissipation fins (33) is 3-8mm, the spacing between the heat dissipation fins (33) is 1-3mm, and the thickness of the heat dissipation fins (33) is 0.5-1.5mm. The through structure is a clearance hole (34), and there are four clearance holes (34). The diameter of the clearance hole (34) is 0.5-1mm larger than the diameter of the mounting and positioning structure. The overall positioning structure is a positioning hole (35), which is located in the middle of the insulating shell (31).

8. A smart meter, characterized in that, The invention includes a manganese-copper shunt assembly as described in any one of claims 1-7, wherein the first shunt (1) and the second shunt (2) of the manganese-copper shunt assembly are connected in series in the live wire and neutral wire circuit of the smart meter, respectively, for simultaneously measuring the current of the live wire and the neutral wire, and detecting leakage in the circuit by comparing the current values ​​of the two.

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