Compact Connector with Integrated Current Sensor
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Solution Overview
Problem
Conventional connector devices with current sensors require additional housing space, increasing their size due to the need for a current sensor and signal connectors at the terminal fitting portion, leading to bulkier designs.
Innovation Solution
A connector device design featuring a current sensor that measures current via magnetic flux in a coupling portion between terminals, with a magnetic core, sensor, and shield member housed in a separate casing portion, and a signal output device projecting from the casing to minimize size increase, allowing for compact integration of current measurement functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a current sensor is disposed at the terminal fitting portion to measure current flowing in the terminal fitting portion, then current measurement function is achieved, but the size of the connector device increases due to required housing space
Solution Approach 1:
The current sensor is extracted from the terminal fitting portion and relocated to a separate housing portion. This separation allows the terminal fitting portion to maintain its original compact size while the current sensor resides in its own dedicated space, resolving the contradiction between achieving current measurement and maintaining small connector size.
Solution Approach 2:
The connector device is segmented into distinct functional portions: the terminal fitting portion for electrical connection and the housing portion for current measurement. This segmentation allows each component to be optimized independently, enabling current measurement functionality without increasing the overall connector device size.
2Ease of operation
If signal connectors are disposed at the terminal fitting portion to supply output signals from the current sensor, then signal transmission function is achieved, but additional housing space is required increasing the connector device size
Solution Approach 1:
The signal connector is merged with the housing portion rather than being separately disposed at the terminal fitting portion. This integration allows the signal transmission function to be achieved while utilizing the existing housing space, thereby avoiding additional size increase of the connector device.
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
This design enables the inclusion of a current sensor while maintaining a compact size, reducing the overall size of the connector device and associated components, and minimizing the impact on connected devices, while also reducing component count and cost.
Implementation Method 1
the magnetic core member having a core body provided with a gap portion that has a slit shape extending in a cylinder axis direction of a cylindrical body internally spaced to surround the coupling portion, the magnetic core member generating magnetic flux according to current flowing in the coupling portion
Implementation Method 2
the magnetic sensor outputting a signal according to magnetic flux density in the gap portion
Implementation Method 3
the magnetic shield member having a shield body that surrounds the core body from outside to block magnetism between the inside and outside of the shield body by using the shield body
Data Source
AI summary
A connector device includes: a connection terminal including a first terminal connection portion electrically connected to a first counterpart terminal, a second terminal connection portion electrically connected to a second counterpart terminal, and a coupling portion having a flat plate shape, disposed between the first terminal connection portion and the second terminal connection portion electrically connected between the first terminal connection portion and the second terminal connection portion; a current sensor configured to measure current flowing in the coupling portion on the basis of magnetic flux according to the current; and a casing including a first housing portion housing the second terminal connection portion, and a second housing portion housing the coupling portion and the current sensor.