Current Sensor Bus Bar Convex Portion Strength
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Solution Overview
Problem
Current sensors face challenges in downsizing and maintaining measurement precision due to the deformation of slimmed bus bars under stress and increased heat generation, which can reduce the strength of the bus bar.
Innovation Solution
The current sensor incorporates a bus bar with a convex portion formed along the extending direction, which enhances the strength of the bus bar and prevents deformation under stress, while also allowing for efficient heat dissipation. Additionally, a narrow-width portion with wide-width portions on either side and a concave portion on the opposite surface improve measurement precision by increasing the components of the induced magnetic field detectable by the magnetic sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the bus bar is slimmed to achieve downsizing and weight reduction, then the size and weight of the current sensor are reduced, but the bus bar may be deformed and its strength reduced when stress is applied
Solution Approach 1:
The invention adds a convex portion that protrudes in the thickness direction (third direction) of the bus bar plate surface. This dimensional addition increases the moment of inertia and structural rigidity without increasing the planar dimensions (first and second directions), thereby maintaining strength while achieving downsizing and weight reduction in the overall sensor package.
Solution Approach 2:
The convex portion is formed at a specific location on the bus bar plate surface, creating a localized reinforcement zone. This local structural modification strengthens the bus bar at the critical area where stress concentration occurs during attachment, without requiring the entire bus bar to be thicker or heavier.
2Length of stationary object
If the bus bar is slimmed to achieve profile reduction, then the height of the current sensor is reduced, but the bus bar may be deformed when stress is applied in a direction causing twisting or bending
Solution Approach 1:
By protruding the convex portion in the thickness direction, the invention increases the effective height and structural depth of the bus bar at the reinforcement location. This creates greater resistance to bending and twisting moments while keeping the overall sensor profile compact, as the convex portion is contained within the sensor housing.
Solution Approach 2:
The convex portion features a curved surface rather than sharp edges, which distributes stress more evenly across the structure. This curvature helps prevent stress concentration points that could initiate deformation or cracking under load, thereby improving structural stability during attachment operations.
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
The enhanced bus bar design allows for profile reduction, downsizing, and weight reduction of the current sensor while maintaining measurement precision and preventing a reduction in bus bar strength due to slimming.
Implementation Method 1
a magnetic sensor 3 that detects a magnetic field generated when a current under test flows in the bus bar 2
Data Source
AI summary
A current sensor has a bus bar and a magnetic sensor. The bus bar has a portion extending in the X direction. A convex portion is formed on a plate surface, which is on the Z2 side, along the X direction, so as to protrude from the plate surface, the plate surface facing the magnetic sensor parallel to an XY plane defined by the X direction and the Y direction orthogonal to the X direction.