Insulating Body Current Measurement with Shielded Hall Sensors
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Solution Overview
Problem
Existing insulating bodies in modular industrial connectors face challenges in compactly integrating sensors to monitor currents flowing through contact elements, due to design constraints and interference issues.
Innovation Solution
The insulating body features a plastic base with metallic core side parts, umbrella arms, and a circuit board with Hall sensors, ensuring precise alignment and electromagnetic shielding, allowing for reliable current measurement without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are integrated into compact insulating bodies, then current monitoring capability is improved, but sensor interference and positioning difficulty worsen
Solution Approach 1:
The insulating body is divided into multiple compartments or designated regions, with each sensor assigned to a specific compartment. This segmentation physically separates the sensors from each other, reducing electromagnetic interference while maintaining compact dimensions. The base body structure includes recesses or cavities that house individual sensors in isolated locations.
Solution Approach 2:
Different regions of the insulating body are designed with locally optimized properties - certain areas provide electromagnetic shielding for sensors, while other regions facilitate easy positioning. The base body incorporates localized features such as shielding materials in specific zones, recesses for sensor mounting, and structural elements that guide sensor placement without requiring complex overall design.
2Measurement precision
If multiple sensors are integrated into the insulating body, then current monitoring capability is improved, but manufacturing cost increases
Solution Approach 1:
Multiple sensors are integrated into a single insulating body component rather than being separate assemblies. The sensors are mounted directly onto the base body or circuit board within the insulating body structure, combining the functions of current monitoring and insulation in one manufactured part. This reduces the total number of components and assembly steps.
Solution Approach 2:
The insulating body serves multiple functions simultaneously: it provides electrical insulation, houses and positions multiple sensors, offers electromagnetic shielding, and facilitates assembly through integrated features. This multi-functionality reduces the need for separate components for each function, lowering overall manufacturing complexity and cost.
3Measurement precision
If sensors are shielded from each other, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The electromagnetic shielding function is extracted as a separate, simple feature of the base body rather than a complex additional structure. The base body incorporates shielding materials or grounded conductive elements in specific locations to isolate sensors from each other's electromagnetic fields, providing necessary shielding without adding overall device complexity.
Solution Approach 2:
The base body is constructed from composite materials that combine insulating properties with electromagnetic shielding capabilities. This allows the same component to provide both electrical insulation and magnetic field shielding for the sensors, eliminating the need for separate shielding structures and reducing overall complexity.
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
This design enables cost-effective, compact, and interference-free current monitoring within the insulating body, ensuring accurate measurements and easy assembly, while allowing integration with other modules in industrial connectors.
Implementation Method 1
The insulating body (1) has at least two sensors (13) for current measurement, in particular Hall sensors (13), assigned to the at least two contact elements (6)
Implementation Method 2
Both side panels are made of plastic, with the first side panel containing a metallic core
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
The invention relates to an insulating body (1) or a module for a modular industrial plug-in connector. At least two electrical contact elements (6) are arranged in the module, each of which is assigned a Hall sensor (13) for current measurement. The Hall sensors (13) are electromagnetically shielded from one another within the module by shielding arms (7).