Current Sensing Device Coil Positioning via Bent Locating Pins
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Solution Overview
Problem
Current sensing devices with multiple coil elements face challenges in precise and economical positioning on substrates, particularly on simple substrates like PCBs, leading to limited positioning precision and inconsistency in signal measurements.
Innovation Solution
The use of a substrate with circular holes and bent locating pins that engage with flanges on the coil elements, allowing for accurate and secure fixation and positioning of the coil elements, ensuring consistent signal measurements across multiple coil elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If basic component placement concepts are used to mount coil elements on a PCB, then ease of manufacture is improved, but manufacturing precision deteriorates
Solution Approach 1:
The locating pin is segmented into two distinct sections: a first section that fits within the PCB hole and a second section that engages with the coil element flange. This segmentation allows each section to perform its specific function optimally - the first section provides precise positioning through the hole while the second section provides secure mechanical engagement with the flange, thereby achieving high positioning precision without complicating the manufacturing process.
Solution Approach 2:
The locating pin acts as an intermediary component between the PCB substrate and the coil element. It mediates the connection by providing both positioning (through the PCB hole) and mechanical engagement (through the flange), thereby enabling precise mounting of coil elements on simple PCB substrates without requiring complex placement mechanisms.
2Reliability
If clearance is increased between connecting pin and PCB hole to reduce stress risk, then reliability is improved, but manufacturing precision deteriorates
Solution Approach 1:
The locating pin is divided into two functional sections: the first section inserted into the PCB hole provides precise positioning with minimal clearance requirements, while the second section engages with the coil element flange to provide mechanical support and stress relief. This segmentation allows the pin to simultaneously achieve high positioning precision and reliability by distributing functions across different sections.
3Ease of operation
If alignment posts are used to facilitate individual placement of bobbin elements, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The locating pin serves as an intermediary component that bridges the PCB substrate and the coil element flange. By engaging with both the PCB hole (for positioning) and the flange (for mechanical engagement), it provides precise positioning while maintaining ease of operation during assembly, eliminating the need for separate alignment posts.
4Strength
If coil elements are firmly fixed using fasteners like screws, then strength is improved, but device complexity increases
Solution Approach 1:
The locating pin merges multiple functions into a single component: it provides positioning (by fitting into the PCB hole), mechanical engagement (by engaging with the flange), and fixation (through the bent sections that provide anchoring). This consolidation eliminates the need for separate fasteners like screws, thereby achieving strong fixation while reducing device complexity.
Solution Approach 2:
The locating pin utilizes parameter changes in its geometry - specifically the bent sections with obtuse angles - to transform a simple insertion pin into a mechanically engaged fixture. The bent sections create anchoring effects that provide strong fixation without requiring additional fasteners, thereby maintaining simplicity while achieving high strength.
Data Source
AI summary
A current sensing device includes a substrate and one or more coil elements. The substrate comprises a plurality of holes extending at least partially through the substrate from a first surface of the substrate. The coil element comprises two locating pins. A first locating pin engages a locating cavity of a first flange and locates in a first hole. A second locating pin engages another locating cavity of a second flange and locates in a second hole. The end of the first locating pin bends to form an obtuse angle. The end of the second locating pin also bends to form an obtuse angle.