Busbar Sensor Holding Structure for Accurate Temperature Detection
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Solution Overview
Problem
Existing busbar units with detachable temperature sensors face challenges in maintaining close contact with the busbar, leading to inaccurate temperature detection.
Innovation Solution
A busbar unit design that includes a sensor holding portion with first and second supporting portions and a coupling portion to sandwich a temperature sensor case, ensuring close contact and accurate temperature detection, along with a covering member made of insulating resin to secure the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the temperature sensor is made detachable from the busbar, then the ease of operation is improved, but the measurement precision deteriorates
Solution Approach 1:
The temperature sensor is divided into a sensor unit (with thermistor element) and a case unit, which can be assembled and disassembled separately. The sensor unit can be detached from the busbar while the case remains, enabling easy operation and replacement without compromising the sensing capability when attached.
Solution Approach 2:
The sensor holding portion is pre-formed with protrusions that fit into corresponding recesses on the sensor unit, and the case is pre-formed with engagement structures. This preliminary preparation of mating features enables quick assembly and disassembly while ensuring precise positioning and stable contact for accurate temperature measurement.
2Ease of repair
If the temperature sensor is made detachable from the busbar, then the ease of repair is improved, but the reliability deteriorates
Solution Approach 1:
The sensor unit is nested within the case structure, with the sensor holding portion integrated into the busbar and the sensor unit fitting into it. The case provides an outer protective structure. This nested arrangement allows the inner sensor unit to be replaced independently while maintaining the overall assembly's reliability through the stable outer case structure.
Solution Approach 2:
The sensor holding portion acts as an intermediary structure between the busbar and the sensor unit, providing a stable mounting interface with protrusion-recess engagement. This intermediary structure ensures reliable positioning and electrical contact while allowing the sensor unit to be replaced without affecting the busbar or the case.
3Device complexity
If the sensor holding portion uses a simple U-shaped structure, then the device complexity is reduced, but the measurement precision deteriorates
Solution Approach 1:
The sensor holding portion is segmented into multiple functional elements: protrusions for positioning, contact surfaces for electrical connection, and engagement features for the sensor unit. This segmentation provides precise positioning and stable contact without requiring a complex overall structure, maintaining simplicity while improving measurement precision.
Solution Approach 2:
The sensor holding portion has different local characteristics: protrusions at specific locations for positioning, flat contact surfaces for electrical connection, and engagement features for mechanical coupling. Each local feature is optimized for its specific function, achieving precise temperature measurement without overall structural complexity.
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 design improves the accuracy of temperature detection on the busbar by maintaining close contact between the temperature sensor and the busbar, while also preventing detachment of the sensor.
Implementation Method 1
the first supporting portion having a first contact surface configured to contact the case, a second supporting portion having a second contact surface facing the first contact surface and configured to contact the case... holds the temperature sensor by sandwiching the case by the first and second contact surfaces
Data Source
AI summary
A busbar unit is provided with a busbar, a temperature sensor and a covering member made of insulating resin for covering the busbar and the temperature sensor. The temperature sensor includes a thermistor element and a case for accommodating the thermistor element. The busbar includes a sensor holding portion for holding the temperature sensor. The sensor holding portion includes a first supporting portion having a first contact surface, a second supporting portion having a second contact surface facing the first contact surface and a coupling portion coupling one end parts of the first supporting portion and the second supporting portion. The sensor holding portion holds the temperature sensor by sandwiching the case by the first contact surface and the second contact surface. The covering member covers outsides of the sensor holding portion and the case.