One-Piece Busbar Geometry for Precise High-Current Measurement
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Solution Overview
Problem
Existing current measurement technologies face challenges in achieving precise and cost-effective measurement of high currents due to phase errors, material transitions, and interference from external magnetic fields, particularly in AC current measurements.
Innovation Solution
A busbar design with a current shadow geometry and integrated temperature compensation, featuring a resistor section with current-free measuring contacts and optimized lead routing to minimize interference and ensure accurate voltage measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional current measuring device (clamp meter, current transformer, or shunt) is used, then current measurement is achieved, but the device is bulky, expensive, and/or requires disassembling electrical equipment
Solution Approach 1:
The busbar serves dual functions: it acts as both the current-carrying conductor and the measurement sensor. The measuring element is integrated directly into the busbar structure, allowing the same component to perform both power transmission and current sensing without requiring separate measurement devices
Solution Approach 2:
The measurement function is merged with the power conductor by embedding the measuring element (such as a strain gauge or piezoelectric sensor) directly into the busbar structure. This integration eliminates the need for separate clamp meters, current transformers, or shunts, thereby reducing device complexity while maintaining measurement capability
2Ease of manufacture
If a measuring element is integrated into the busbar, then device size is reduced and installation is simplified, but the busbar structure becomes more complex
Solution Approach 1:
The busbar is divided into distinct functional segments: current-carrying sections and measurement sections. The measuring element is integrated into specific locations where it can sense current without interfering with the overall busbar assembly, allowing for modular manufacturing and installation
Solution Approach 2:
The measuring element is integrated only at specific locations on the busbar where current measurement is required, rather than throughout the entire structure. This localized integration minimizes the impact on overall busbar design while providing necessary measurement functionality
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 achieves high measurement accuracy and cost-effectiveness by minimizing phase errors and material transitions, allowing precise current measurement across a wide range of frequencies and temperatures.
Implementation Method 1
the measuring element (13) is adapted to detect current flowing through the busbar (10) by means of a physical quantity, in particular temperature, force or voltage
Implementation Method 2
the measuring element (13) is adapted to detect current flowing through the busbar (10) by means of a physical quantity, in particular temperature, force or voltage
Implementation Method 3
the measuring element (13) is adapted to detect current flowing through the busbar (10) by means of a physical quantity, in particular temperature, force or voltage
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3a~3b
AI summary
A busbar (11, 14) for measuring a direct and/or alternating current, in particular with current intensities of greater than 100 amperes, has connection regions (11a) and at least one resistance region (11b) which is arranged between the connection regions (11a) and has two measuring contacts (12) arranged in the resistance region (11b), wherein the busbar (11, 14) has a geometry in which the regions of the measuring contacts (12) are substantially deenergized during operation of the busbar (11, 14), wherein the busbar (11, 14) is formed in one piece. An apparatus (10) for determining current and having such a busbar (11, 14) and a power converter having such an apparatus are also disclosed.