Current Detection Device Terminal Flange Burial
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Solution Overview
Problem
Current detection devices face issues with displacement and resistance value changes due to high-temperature welding or soldering processes, leading to precision loss and complex manufacturing processes, particularly with protruding portions and tolerance-related challenges in controlling terminal lengths.
Innovation Solution
A current detection device design featuring conductors with a resistor between them, where detection terminals have a first and second flange with specific dimensions and orientations, allowing for precise control of terminal lengths and avoiding protrusions, using a manufacturing method that includes forming holes in the conductors and inserting terminal portions with flanges to ensure smooth integration and reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface welding or surface soldering processes are used to manufacture the current detection device, then the electrodes can be connected to the resistor, but the detection terminal displaces and resistance value changes due to high-temperature environment
Solution Approach 1:
The detection terminal is divided into a first terminal portion inserted into the conductor and a second terminal portion protruding from the conductor surface. The first terminal portion includes a first flange and a second flange, with the gap between them filled by conductor material, creating a segmented structure that prevents displacement during welding while maintaining connection precision.
Solution Approach 2:
The first terminal portion is inserted into and nested within the conductor, with the first flange buried into the conductor and the second flange extending outward. This nested configuration anchors the detection terminal securely within the conductor, preventing displacement during high-temperature welding processes.
2Reliability
If protruding portions are formed on the electrode surface to fix the voltage detection terminal, then the terminal can be secured, but the manufacturing process becomes more complicated and requires additional recesses
Solution Approach 1:
The fixation function and the conductor structure are merged into a single integrated design. The first flange and second flange of the detection terminal are directly formed as part of the terminal structure, with the gap between them filled by conductor material, eliminating the need for separate recesses and protruding portions.
Solution Approach 2:
The complex multi-step process of forming protruding portions and recesses is extracted and replaced by a simpler direct insertion method. The detection terminal is inserted directly into the conductor with the flanges positioned to fill the gap, eliminating unnecessary manufacturing steps while maintaining secure fixation.
3Manufacturing precision
If the length of the probe portion is not effectively controlled, then manufacturing tolerance affects the dimension, but precise control within predetermined dimension is difficult
Solution Approach 1:
The conductor material is pre-formed with a hole of precise dimensions before the detection terminal is inserted. The hole's dimensions are carefully controlled in advance, which directly determines the length of the second terminal portion after insertion, enabling precise length control without complex post-processing.
Solution Approach 2:
The design changes the critical parameter from terminal length to hole dimension. By controlling the hole's dimensions in the conductor and using the flanges to fill the gap, the second terminal portion's length is determined by the hole's dimensions, which can be more precisely controlled during conductor manufacturing.
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
A current detection device including two conductors, a resistor and two detection portions is provided. The resistor is disposed between the two conductors. At least one of the detection portions is a detection terminal including a first terminal portion and a second terminal portion. The first terminal portion includes a first flange and a second flange, the second flange is connected to the second terminal portion, and at least one portion of the second flange is buried into at least one conductor. The first flange is buried into the at least one conductor, a distal end of the first flange does not protrude beyond the second surface, a distance is kept between the distal end of the first flange and the second surface, a gap is defined between the first flange and the second flange, and at least one portion of the gap is filled with a material of the at least one conductor.