Integrated Current Detector with Terminal Block
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Solution Overview
Problem
Conventional power converters face challenges in reducing size and height due to the arrangement of current detectors and terminal blocks, which also complicate the assembly process and lack sufficient mechanical strength and flexible terminal connection options.
Innovation Solution
A terminal block-integrated current detector is designed with a current detection unit and terminal block merged together, featuring magnetic cores with penetration holes and conductor bars connecting to terminal portions, reducing height and volume while ensuring mechanical strength and flexible terminal connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If current detectors and terminal blocks are arranged separately in conventional power converters, then the connection between inverter unit and output terminal block is established, but the size of the power converter increases in the arrangement direction and the height increases due to the greater diameter of cores
Solution Approach 1:
The patent merges the current detector and terminal block into a single integrated component. The terminal block is positioned at the end of the current detector's core structure, eliminating the need for separate arrangement and reducing the overall occupied volume while maintaining both current detection and terminal connection functions
2Length of stationary object
If terminal blocks are arranged above current detectors as in JP 2013-048539A, then the size in the extending direction is reduced, but the height is rather increased
Solution Approach 1:
Instead of arranging terminal blocks above current detectors in the vertical direction (increasing height), the patent positions the terminal block at the end of the core structure in the horizontal extending direction. This dimensional reorganization reduces height while maintaining compact size in the extending direction
3Reliability
If multiple current detectors are fixed to terminal blocks independently via terminal-side power bus bars, then terminal connections are established, but the structure becomes complicated and fragile
Solution Approach 1:
The patent integrates the terminal block as an inherent part of the current detector structure rather than treating them as separate components. This merging eliminates the need for multiple independent fixings via terminal-side power bus bars, simplifying the assembly structure and reducing fragility while ensuring reliable terminal connections
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 achieves a reduced occupied volume, simplified assembly, and enhanced mechanical strength with flexible terminal connections, addressing the size and height limitations of conventional power converters.
Implementation Method 1
a current detection unit (100) including a plurality of cores (101a, 101b, 101c) made of magnetic material
Data Source
AI summary
A current detector includes: a current detection unit including a plurality of cores made of magnetic material, in the plurality of penetration holes are penetrating through, respectively; a terminal block including a plurality of terminal connecting portions being arranged side by side in a direction perpendicular to an axial direction of the penetration holes, the terminal block being merged with the current detection unit; and a plurality of conductor bars, each having one end inserted into one of the penetration holes and another end connected to corresponding one of the terminal connecting portions.