Bus Bar Sensor Bracket Assembly for Vibration-Stable Mounting
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Solution Overview
Problem
Existing pass-through current sensors for bus bars face accuracy issues due to misalignment caused by shock or vibration, and require permanent modifications for installation, making replacement and installation difficult.
Innovation Solution
A two-piece bracket assembly that securely mounts a pass-through current sensor to a bus bar without direct contact, using channels and fasteners to rigidly couple the sensor and bus bar, allowing for accurate measurements without additional structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pass-through sensor is mounted to a bus bar using permanent modifications (drilling holes or mechanical bonds), then the sensor is securely fixed and does not move, but the installation process becomes complex and replacement of components becomes difficult
Solution Approach 1:
The mounting system is divided into separate modular components: a sensor mount that attaches to the bus bar and a sensor that attaches to the mount. This segmentation eliminates the need for permanent modifications to the bus bar while maintaining secure fixation, as each component can be independently installed and replaced.
Solution Approach 2:
A sensor mount acts as an intermediary component between the bus bar and the sensor. This intermediate element provides a secure mounting interface without requiring direct permanent attachment to the bus bar, thereby simplifying installation and replacement while maintaining reliability.
2Measurement precision
If a separate rigid element is used to support the sensor mount, then the sensor is held in the desired position, but the system requires additional structural support and becomes more complex
Solution Approach 1:
The bus bar itself serves as the support structure for the sensor mount, eliminating the need for separate rigid support elements. The mount is designed to attach directly to the bus bar and provide the necessary positioning and rigidity, allowing the system to support itself without additional structural components.
3Reliability
If the line is rigidly coupled within the sensor, then the sensor and line are fixed together, but the installation requires permanent modifications and limits installation areas
Solution Approach 1:
The connection system is segmented into removable modular components that can be attached and detached without permanent modifications. This allows the same mounting system to be applied to various bus bar configurations and locations, enhancing installation flexibility while maintaining connection stability.
Solution Approach 2:
The mounting system transitions from a static permanent attachment to a dynamic removable attachment. The sensor mount can be installed and removed as needed, allowing the system to adapt to different installation locations and bus bar configurations while maintaining reliable connection during operation.
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
The assembly provides stable, accurate current measurements by preventing relative movement between the sensor and bus bar, allowing easy installation and replacement without damaging the bus bar, and reducing noise interference.
Implementation Method 1
a pass-through style sensor, an example of which is a hall effect sensor
Data Source
AI summary
A bracket assembly for supporting a pass-through current sensor with respect to a bus bar is disclosed. The bracket assembly has two sections which each contain channels that conform to the shape of one or more segment of the bus bar. The sections are configured to couple to one another over the segments such that the bracket assembly is clamped to the bus bar. An aperture in the current sensor is passed over the bus bar and the sensor is coupled to the bracket assembly, thereby indirectly coupling the bus bar to the sensor.