Current Sensing Device Voltage Terminal Positioning
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Solution Overview
Problem
Existing current sensing devices face challenges in maintaining high positional accuracy for voltage sensing terminals, which affects the accuracy of current sensing, particularly when resistance values are low, and are prone to errors due to tightening torque or uneven surface joining.
Innovation Solution
A current sensing device with voltage sensing terminals formed by inserting bar-like metal into through-holes in an electrical conductor, where the terminals include a first terminal portion stored within the hole and a second portion protruding, and a flange for stable fixation, ensuring high positional accuracy through precise machining and positioning during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If voltage sensing terminals are formed by stamping and screw formation, then the terminals can be securely fastened, but the sensing accuracy may be influenced by tightening torque or loosening
Solution Approach 1:
The patent replaces the mechanical screw fastening system with a through-hole insertion system where bar-like metal terminals pass through holes in the electrical conductor. This eliminates tightening torque and loosening issues while maintaining secure electrical contact through the through-hole structure.
Solution Approach 2:
The through-hole acts as an intermediary structure that secures the voltage sensing terminals without requiring direct mechanical fastening. The hole provides geometric constraint and positional stability, mediating between the terminal and the electrical conductor body.
2Strength
If measuring terminal portions are welded to the surfaces of base materials, then the terminals can be firmly attached, but it is difficult to maintain the positional accuracy
Solution Approach 1:
The patent replaces the welding process with a through-hole insertion method. The bar-like metal terminals are inserted through precisely machined holes, eliminating the need for welding and the associated positional accuracy issues that arise from heat-affected zones and material distortion.
Solution Approach 2:
The through-holes are pre-formed in the electrical conductor at precise positions before the terminals are inserted. This preliminary positioning action ensures that the voltage sensing terminals are placed with high positional accuracy, independent of subsequent attachment processes.
3Device complexity
If measuring terminals and base materials are joined at their surfaces, then the structure can be simplified, but high-accuracy sensing is difficult unless the surfaces are joined uniformly
Solution Approach 1:
The through-hole serves as an intermediary structure that provides precise positioning and secure retention for the voltage sensing terminals. This simple geometric feature eliminates the need for complex surface joining mechanisms while ensuring high sensing accuracy through consistent terminal placement.
Data Source
AI summary
Provided is a current sensing device including an electrical conductor made of electrically conductive metal; and voltage sensing terminals provided on the electrical conductor. Each voltage sensing terminal is formed by inserting bar-like metal into a through-hole formed in the electrical conductor, and the voltage sensing terminal includes a first terminal portion that is stored in the through-hole and a second terminal portion that protrudes from the through-hole.