Integrated Shunt Contactor for Space-Saving Current Sensing
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Solution Overview
Problem
Existing contactors in electrically driven vehicles face challenges in efficiently measuring current flow while minimizing installation space and weight.
Innovation Solution
Integration of a shunt resistor as part of the connecting element within the contactor, allowing precise current measurement by using the connecting element itself as a measuring resistor, with temperature compensation and control units for enhanced accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate shunt resistor is installed to measure current, then current measurement capability is improved, but installation space and device complexity increase
Solution Approach 1:
The patent combines the connecting element (busbar) with the shunt resistor function into a single integrated component. The connecting element itself is designed with specific geometric dimensions and material properties to serve as the measuring resistor, eliminating the need for a separate shunt resistor installation and reducing overall device space requirements.
Solution Approach 2:
The connecting element performs multiple functions simultaneously: it provides electrical connection between contact elements and serves as the measuring resistor for current measurement. This multi-functionality approach eliminates the need for dedicated separate components, reducing installation space and device complexity.
2Measurement precision
If a separate shunt resistor is installed to measure current, then current measurement capability is improved, but device weight increases
Solution Approach 1:
The patent combines the connecting element (busbar) with the shunt resistor function into a single integrated component. The connecting element itself is designed with specific geometric dimensions and material properties to serve as the measuring resistor, eliminating the need for a separate shunt resistor installation and reducing overall device space requirements.
Solution Approach 2:
The connecting element performs multiple functions simultaneously: it provides electrical connection between contact elements and serves as the measuring resistor for current measurement. This multi-functionality approach eliminates the need for dedicated separate components, reducing installation space and device complexity.
3Area of stationary object
If the connecting element is used as a measuring resistor, then installation space is reduced, but measurement precision may be affected by mechanical stability requirements
Solution Approach 1:
The patent applies local quality by designing specific portions of the connecting element with optimized geometric dimensions and material properties tailored for precise resistance measurement. The connecting element is engineered with controlled cross-sectional areas and lengths in specific regions to ensure stable and precise electrical resistance characteristics while maintaining its mechanical connection function.
Solution Approach 2:
The patent utilizes parameter changes by carefully selecting and controlling the geometric parameters (length, cross-sectional area) and material properties of the connecting element to achieve a specific, stable resistance value. By adjusting these parameters, the connecting element is optimized to serve as a precise measuring resistor while maintaining mechanical stability.
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
Enables efficient and precise current measurement with reduced space and weight, facilitating reliable contactor status monitoring and diagnostics, including detection of jamming and wear.
Implementation Method 1
the voltage that drops across the measuring component due to the current flowing through the measuring component can be measured via the measuring lines
Data Source
AI summary
A contactor has a first contact element and a second contact element as well as an electrically conductive connecting element. An actuator is designed to move the connecting element between a closed state and an open state, wherein, in the closed state, an electrically conductive connection between the first contact element and the second contact element is effected via the connecting element and, wherein, in the open state, no electrically conductive connection between the first contact element and the second contact element is effected by the connecting element. At least one measuring component of the connecting element is in the form of a measuring resistor. Measuring lines are electrically conductively connected to different ends of the measuring component so that a voltage that drops across the measuring component due to the current flowing through the measuring component can be measured via the measuring lines.