Current Sensor Nut Shaving Containment via Segmented Cover
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Solution Overview
Problem
Existing current sensors face issues with shavings generated during the fastening process potentially escaping and causing trouble, and there is a risk of insulation failure due to irrelevant matter entering the sensor through exposed parts.
Innovation Solution
A current sensor design that includes a bus bar, a nut for external terminal connection, a magnetic sensor for detecting the magnetic field, a case member that seals the bus bar and nut, and a cover member with an insulative protective member covering the open part where the nut is exposed, preventing shavings and irrelevant matter from entering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the nut is integrally molded in the case by insert molding, then the electrical coupling between the nut and conductor is assured, but shavings generated when a bolt is screwed into the nut may drop to the outside and cause trouble
Solution Approach 1:
The invention divides the case into two separate parts: the case body and the cover. The nut is integrally molded in the case body, while the cover is equipped with a protective member that covers the open part of the case body. This segmentation allows the nut to maintain its electrical coupling function while the protective member prevents shavings from escaping during the fastening process.
Solution Approach 2:
The protective member acts as an intermediary element between the nut and the external environment. It covers the open part of the case body where the nut is exposed, preventing shavings generated during bolt fastening from dropping outside, while still allowing the bolt to access and fasten to the nut.
2Stability of the object's composition
If the nut is integrally molded in the case, then the nut is securely retained, but an exposed part remains where irrelevant matter may enter and cause insulation failure
Solution Approach 1:
The case is segmented into the case body containing the retained nut and the separate cover with protective member. This segmentation allows the nut to remain securely retained in the case body while the protective member covers the exposed open part, preventing irrelevant matter from entering and causing insulation failure.
Solution Approach 2:
The protective member serves as an intermediary barrier that covers the open part of the case body where the nut is exposed. It prevents irrelevant matter from entering the internal space while maintaining the secure retention of the nut through the integrally molded connection with the case body.
3Ease of manufacture
If the conductor is made to project from the case for external terminal fastening, then no retaining pins are needed, but retaining jigs are required during fastening work making the process complicated
Solution Approach 1:
The case body serves multiple functions: it houses the magnetic sensor, provides structural support, and includes the open part that allows direct access to the nut for fastening operations. The protective member on the cover further enhances this by allowing bolt access while protecting internal components. This multi-functionality eliminates the need for separate retaining jigs during fastening.
Solution Approach 2:
The fastening function is extracted from the internal structure by providing direct access to the nut through the open part of the case body. The nut is positioned such that it can be accessed from the outside through the open part, allowing direct fastening operations without requiring retaining jigs to hold the conductor or bus bar in place.
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 solution effectively prevents shavings from escaping and irrelevant matter from entering the sensor, thus avoiding insulation failure and simplifying the fastening process by eliminating the need for retaining jigs.
Implementation Method 1
a magnetic sensor capable of detecting a magnetic field generated when a current flows through the bus bar
Data Source
AI summary
A current sensor according to the present invention includes a bus bar through which a measuring current flows; a nut with which the bus bar and an external terminal are brought into contact with and fastened to each other; a magnetic sensor capable of detecting a magnetic field generated when a current flows through the bus bar; a case member having a housing area in which the magnetic sensor is allowed to be housed, the case member sealing the bus bar and the nut inside; and a cover member provided over the housing area. The case member has an open part in which a portion of the nut is exposed. The open part is covered by an insulative protective member. Therefore, shavings generated when a bolt for fastening an external terminal is screwed into the nut are prevented from dropping to the outside of the current sensor.