Conductive Connection Part With Locking Pins for Current Sensing
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Solution Overview
Problem
There is a need for a simple, reliable, and effective solution to measure variations in the intensity of currents flowing in the phase connectors or battery connectors of electric or hybrid vehicle electrical assemblies, particularly in the context of high-voltage power systems used in electric motor control.
Innovation Solution
An electrical conduction part with a flat conductive portion and extending connection pins allows direct contact with the electronic control unit, facilitating current measurement and featuring anti-rotation and locking mechanisms to secure the part during assembly, made from conductive materials like copper, steel, or aluminum with an anti-wear surface for enhanced durability and compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple electrical connection is used between the external terminal and the electronic control unit, then the device complexity is reduced, but the measurement precision of current intensity variations deteriorates
Solution Approach 1:
The electrical connection part is segmented into distinct functional zones: a flat conductive portion for terminal contact, intermediate connection pins for electrical connection, and locking portions for mechanical retention. This segmentation allows each zone to be optimized for its specific function while maintaining overall simplicity
Solution Approach 2:
The electrical connection part serves multiple functions simultaneously: it provides electrical conduction for current measurement, mechanical locking for secure mounting, and structural support for the connection pins. This multi-functionality reduces the need for separate components, thereby simplifying the overall device structure while maintaining measurement precision
2Reliability
If the electrical connection part is securely fixed to prevent rotation and movement, then the reliability under vibration is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The locking portions are merged directly into the body of the electrical connection part as integral features, eliminating the need for separate locking components. This integration maintains secure fixation against rotation and movement while simplifying the manufacturing process through reduced part count and assembly steps
Solution Approach 2:
The locking portions are strategically positioned at specific locations on the electrical connection part to provide targeted anti-rotation and anti-movement capabilities. This localized approach ensures reliability under vibration only where needed, while maintaining ease of manufacture by avoiding complex overall structural modifications
3Reliability
If the flat portion is made larger to improve electrical contact, then the electrical conductivity is improved, but the area available for locking mechanisms is reduced
Solution Approach 1:
The locking portions extend in a direction perpendicular to the flat portion's main surface, utilizing the vertical dimension rather than competing for horizontal space. This dimensional transition allows the flat portion to maintain adequate size for electrical contact while providing sufficient area for effective locking mechanisms
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
Enables precise measurement of current intensity variations, enhances assembly reliability by preventing damage from vibrations, and simplifies the manufacturing process through easy formation of components, ensuring effective electrical contact and corrosion resistance.
Implementation Method 1
at least one electrical connection pin extending from an edge of the flat portion and comprising a connecting end connected to the flat portion, at least one intermediate portion and at least one free end connected to said connecting end by said at least one intermediate portion
Data Source
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AI summary
The invention relates to an electrically conductive part (30) for an electrical assembly (1) comprising an electronic power module (10) and an electronic control unit (20) of said electronic power module (10), said electronic power module (10) comprising an external electrical terminal (121, 122, 123). Said part (30) is designed to electrically connect said external electrical terminal (121, 122, 123) to the electronic control unit (20) and comprises an electrically conductive flat portion designed to be electrically connected to the external electrical terminal (121, 122, 123), and at least one electrical connection pin extending from an edge of the flat portion and comprising a connection end connected to the flat portion, at least one intermediate portion, and at least one free end connected to said connecting end by said at least one intermediate portion, said at least one free end being designed to be electrically connected to the electronic control unit (20).