Current Sensor Bus Bar Structure for Case Stress Relief
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Solution Overview
Problem
Conventional current sensors face damage due to stress applied to the case when the bus bar is connected to a detection target, leading to potential damage from deformation.
Innovation Solution
The current sensor design includes a bus bar with extension portions that deform easily, absorbing stress energy and reducing the stress applied to the case, thereby preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is rigidly fixed to ensure stable current conduction, then electrical connection reliability is improved, but stress concentration on the case occurs during connection leading to potential damage
Solution Approach 1:
The bus bar is divided into a current path portion and extension portions. The extension portions are designed with different cross-sectional areas than the current path portion, creating a segmented structure that allows differential deformation. This segmentation enables the extension portions to absorb connection stress while the current path portion maintains rigid electrical connection properties.
Solution Approach 2:
Different portions of the bus bar are given different mechanical properties through varying cross-sectional areas. The extension portions have reduced cross-sectional area to increase deformability and stress absorption capability, while the current path portion maintains standard cross-sectional area for reliable current conduction. This local differentiation resolves the contradiction between rigidity and stress absorption.
2Stress or pressure
If the bus bar cross-sectional area is reduced to improve deformability and stress absorption, then stress reduction on case is improved, but current conduction capability deteriorates
Solution Approach 1:
The bus bar structure is segmented into two functional zones: the current path portion with standard cross-sectional area for optimal current conduction, and the extension portions with reduced cross-sectional area for stress absorption. This segmentation allows each zone to be optimized for its specific function without compromising the other.
Solution Approach 2:
The cross-sectional area of the bus bar is varied locally - maintained at standard size in the current path portion for electrical performance, and reduced in the extension portions for mechanical compliance. This local quality differentiation enables simultaneous optimization of current conduction capability and stress absorption.
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 design effectively reduces stress on the case by allowing the bus bar's extension portions to deform, thus protecting the case and its components from damage during connection.
Implementation Method 1
a detection element arranged in the gap and configured to detect an intensity of a magnetic field generated by an electric current flowing through the current path portion
Data Source
AI summary
A bus bar of a current sensor includes a side face of a current path portion intersecting with a width direction, a first extension portion extending in the width direction from a region of the side face where the current path portion protrudes from a case, a second extension portion connected to the first extension portion and extending in a direction intersecting with the direction in which the first extension portion extends, and when the current path portion deforms in the thickness direction, the second extension portion deforms in a thickness direction while coming into contact with the case.