Folded Busbar Current Sensor for Installability
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Solution Overview
Problem
Current electric current measuring devices require large installation spaces due to long busbars, which compromises installability and vibration resistance, and increasing busbar length to enhance voltage drop can lead to accuracy issues and increased heat generation.
Innovation Solution
A current measuring device with a busbar featuring a turned portion that maintains a long current flow path while reducing the interval between securement points, embedded in a resin-molded case for improved installability, vibration resistance, and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the busbar is made longer in length to increase voltage drop for accurate current measurement, then measurement precision is improved, but installability and vibration resistance deteriorate due to increased space requirements
Solution Approach 1:
The busbar is configured with a folded shape that extends in multiple spatial dimensions rather than a single straight line. This allows the current flow path length to be increased while keeping the overall projection length short, resolving the contradiction between measurement precision and installability
2Measurement precision
If the busbar is made longer in length to increase voltage drop, then measurement precision is improved, but vibration resistance deteriorates due to increased susceptibility to vibration
Solution Approach 1:
By folding the busbar in multiple dimensions, the effective current path length is increased without proportionally increasing the exposed length susceptible to vibration. The folded structure provides mechanical stability while maintaining electrical path length for accurate measurement
3Measurement precision
If the busbar is made wider and thinner to increase voltage drop, then measurement precision is improved, but heat generation increases causing resistance fluctuation
Solution Approach 1:
Instead of increasing voltage drop by making the busbar wider and thinner (which increases heat generation), the invention achieves increased voltage drop by extending the current flow path in multiple dimensions while maintaining appropriate cross-sectional dimensions for heat dissipation
4Measurement precision
If the busbar projecting length from the negative terminal is increased, then voltage drop increases for better measurement, but the space required for installation increases
Solution Approach 1:
The busbar is configured to extend in multiple spatial dimensions with folded portions, allowing the current flow path length to be increased while keeping the projection length from the terminal short, thus achieving sufficient voltage drop without requiring excessive installation space
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 configuration enhances installability and vibration resistance while maintaining high current-measuring accuracy and reducing temperature rise through effective heat transfer, thereby improving overall device performance.
Implementation Method 1
the amount of heat generation from the busbar might increase
Implementation Method 2
reducing temperature rise through effective heat transfer
Data Source
AI summary
In a current measuring device for measuring an electric current flowing through between a terminal of a battery and a wire, a resistance member has a length and first and second ends in a direction of the length. The first end is to be secured electrically to the terminal of the battery. The second end is to be secured electrically to the wire. The resistance member constitutes a current flow path between the terminal of the battery and the wire. The resistance member has a turned portion through which the current flow path extends. The current measuring device includes a circuit board in which a current measuring circuit is installed. The current measuring circuit measures an electric current flowing through the resistance member based on a potential difference between two different points defined on the resistance member.