Current Sensor Mounting Adapter Bus Bar Alignment
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Solution Overview
Problem
Current sensors face accuracy issues due to a large center hole that prevents direct mounting to conductors, requiring separate frameworks and shims for alignment, which is time-consuming and costly.
Innovation Solution
A mounting adapter that connects to the current sensor and bus bar, providing secure alignment and support, eliminating the need for separate frameworks and allowing quick installation by locking the bus bar into place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate framework is used to support the current sensor, then the current sensor can be mounted, but the alignment of the bus bar to the current sensor becomes complex and time-consuming
Solution Approach 1:
The patent combines the support framework and alignment functions into a single integrated mounting bracket. The bracket includes a bus bar interface that directly receives and positions the bus bar, while simultaneously providing support for the current sensor. This eliminates the need for separate alignment operations and shims, reducing installation time while maintaining mounting capability.
Solution Approach 2:
The mounting bracket acts as an intermediary component that mediates between the bus bar and the current sensor. It includes a bus bar aperture that receives the bus bar and provides precise positioning, while also incorporating mounting features for the current sensor. This intermediary structure simplifies the interface between components and automates the alignment process.
2Manufacturing precision
If shims are used to adjust the framework for centering the bus bar, then alignment precision is improved, but installation complexity and cost increase
Solution Approach 1:
The mounting bracket is pre-designed with a bus bar aperture of specific dimensions that automatically center the bus bar when inserted. The aperture size is precisely engineered to match the bus bar dimensions, ensuring proper positioning without requiring post-installation adjustment with shims. This preliminary design approach achieves high precision while reducing complexity.
Solution Approach 2:
The mounting bracket is designed to self-align the bus bar through its aperture geometry. When the bus bar is inserted into the aperture, the fit automatically centers it relative to the current sensor mounting surface. This self-aligning mechanism eliminates the need for manual adjustment with shims, reducing both complexity and installation steps while maintaining high precision.
3Measurement precision
If the bus bar aperture in the mounting adapter is sized to receive the bus bar, then alignment is improved, but the bus bar must fill the entire aperture space to lock the adapter
Solution Approach 1:
The mounting bracket employs local quality by creating a tight-fit aperture region specifically designed to receive and lock the bus bar. The aperture dimensions are precisely matched to the bus bar size in the critical locking zone, ensuring both precise alignment and strong mechanical engagement. This localized precision fitting provides both alignment and locking functions without requiring the entire aperture to be filled.
Data Source
AI summary
Apparatus and associated methods relate to a mounting adapter which connects to a current sensor and provides an alignment of a bus bar to the current sensor while securely mounting the current sensor to the bus bar. In some embodiments, a mounting adapter may be inserted into an aperture of the current sensor. A bus bar may then be inserted into an aperture in the mounting adapter sized to receive the bus bar and to align it within the current sensor. The bus bar may substantially fill the entire aperture space which may lock the mounting adapter to the current sensor. In some embodiments the bus bar may be secured to the mounting adapter. The secure alignment and coupling of the bus bar to the current sensor via an exemplary mounting adapter may eliminate the need for separate mounting and alignment of the bus bar and current sensor.