Current Detector Core With Resin Bridge Gaps
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Solution Overview
Problem
The formation of gaps in core pieces for electric current detectors can lead to variations in cross-sectional area and looseness, affecting magnetic permeability and linearity, especially when using wound cores, and makes it difficult to maintain paired core pieces from the same core main body.
Innovation Solution
The core pieces are cut with resin partial moldings that include bridge portions to maintain connection and prevent separation, allowing for consistent gap areas and reduced stress, enabling stable magnetic characteristics and linearity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaps are formed in the core main body to improve magnetic characteristics, then magnetic saturation characteristics are adjusted, but cross-sectional area variation and looseness occur affecting magnetic permeability and linearity
Solution Approach 1:
A resin component is introduced as an intermediary substance to fill the gaps between core pieces. This resin component acts as a mediator that prevents direct contact between opposing core piece surfaces, thereby maintaining consistent magnetic path length and cross-sectional area while allowing gaps to be formed for magnetic saturation control.
Solution Approach 2:
The physical state of the resin component is utilized - in its liquid or soft state during assembly, it flows into and fills the gaps between core pieces. After curing or hardening, it maintains a rigid structure that prevents core piece separation, thus controlling the magnetic path parameters consistently while allowing gap formation.
2Reliability
If core pieces are cut from the same core main body to maintain pairing, then magnetic characteristics are stable, but assembly complexity increases
Solution Approach 1:
The resin component merges multiple functions into a single element: it fills gaps, prevents core piece separation, and provides structural support. This consolidation simplifies assembly by eliminating the need for separate fastening mechanisms or complex alignment procedures, while still maintaining the pairing of core pieces from the same core main body.
Solution Approach 2:
The resin component performs self-alignment and self-securing functions. During assembly, the liquid or soft resin automatically flows into the gap spaces between core pieces, and upon curing, it naturally locks the core pieces in their correct positions without requiring additional fastening operations or complex assembly procedures.
3Manufacturing precision
If resin partial moldings with bridge portions are used to prevent core piece separation, then magnetic permeability is maintained, but manufacturing complexity increases
Solution Approach 1:
The resin component is designed with segmented or integrated bridge portions that extend into the gaps between core pieces. These bridge portions are strategically positioned to provide structural support where needed while leaving other areas open for magnetic flux paths. The segmentation allows the resin to be manufactured as a single piece that can be easily installed, reducing overall manufacturing complexity.
Solution Approach 2:
The resin partial molding with bridge portions is pre-formed or pre-assembled before final core assembly. This preliminary action allows the resin structure to be prepared in advance with precise geometry, ensuring consistent magnetic permeability while simplifying the final assembly process where the pre-formed resin component is simply installed into position.
Data Source
AI summary
The present invention provides a core for an electric current detector in which a plurality of gaps can be formed while the paring of core pieces is maintained, and a method for manufacturing the same. A core for an electric current detector 10 according to the present invention includes: a pair of core pieces 20 and 23 that are obtained by cutting an annular core main body 12 in a radial direction at two positions and are arranged such that cross-sectional surfaces 21 and 24 are opposed to each other with a first gap 26 and a second gap 28 being interposed therebetween; and a first partial molding 30 and a second partial molding 40 that are made of resin and cover portions of the peripheral surfaces of the cross-sectional surfaces of the core pieces opposed to each other with the first gap and the second gap being interposed therebetween. The first partial molding includes a bridge portion 33 that serves as a connection portion and spans the gap.