Current Sensor Bus Bar Penetration for Terminal Connection
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Solution Overview
Problem
Current current sensor devices face challenges in assembling with plate-shaped terminals due to burr generation during the pressing of metal bus bars, which affects the positioning and connection reliability, requiring additional positioning members like clamps.
Innovation Solution
Incorporating a penetration portion in the bus bar with opposing wall surfaces that can accommodate terminal variations in thickness direction, allowing for connection without clamps and burr interference, and maintaining a consistent plate thickness direction to reduce positional variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal bus bar is pressed to connect with a plate-shaped terminal, then electrical connection is established, but burrs are generated on the bus bar surface affecting positioning precision
Solution Approach 1:
The bus bar end is segmented into a connection portion and a non-connection portion. The connection portion is pressed to form electrical connection, while the non-connection portion maintains a smooth surface without burrs for precise positioning. This segmentation allows differential treatment of surface quality in different functional zones.
Solution Approach 2:
Different surface qualities are applied to different portions of the bus bar. The connection portion has a pressed surface with burrs for reliable electrical connection, while the non-connection portion has a smooth surface for accurate positioning. This local quality differentiation resolves the contradiction between connection reliability and positioning precision.
2Manufacturing precision
If additional positioning members like clamps are added to accommodate burr generation, then positioning accuracy is maintained, but device complexity increases
Solution Approach 1:
The positioning function is extracted from the connection portion and assigned to a dedicated non-connection portion. This separate positioning structure eliminates the need for additional clamps or positioning members, reducing device complexity while maintaining positioning accuracy.
Solution Approach 2:
The non-connection portion serves multiple functions: it provides precise positioning for the bus bar and simultaneously acts as a reference surface for alignment. This multi-functionality eliminates the need for separate positioning members, simplifying the overall structure.
3Adaptability or versatility
If the bus bar thickness varies in the thickness direction, then assembly flexibility is improved, but positional variations increase
Solution Approach 1:
The positioning reference is shifted from the thickness direction to the width direction. The non-connection portion provides a stable reference surface in the width direction, while the thickness direction can accommodate variations for assembly flexibility. This dimensional shift resolves the contradiction between adaptability and precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the assembling property of current sensor devices by ensuring reliable connections with plate-shaped terminals without the need for positioning members, even with burr formation, and minimizes positional variations due to consistent bus bar thickness.
Implementation Method 1
a magnetoelectric conversion element that is configured to detect a current flowing through the bus bar
Data Source
AI summary
A current sensor device includes a bus bar that is to be connected to a plate-shaped terminal of a semiconductor device, a magnetoelectric conversion element that is configured to detect a current flowing through the bus bar, and a resin portion that integrally holds the magnetoelectric conversion element and the bus bar. The bus bar has one end protruding from the resin portion, and the one end of the bus bar includes a penetration portion defined by wall surfaces. The wall surfaces includes a pair of opposing wall surfaces opposing to each other. At least one of the opposing wall surfaces is configured to be connected to the terminal.