Measuring Resistor Assembly With Probe Positioning Features
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing current measurement systems in electronic circuits, particularly in battery management systems of electric or hybrid vehicles, face challenges in achieving accurate and reliable measurements due to temperature dependence of terminal element materials and the need for precise positioning of voltage taps, which complicates the measurement of voltage drops across resistors.
Innovation Solution
A resistor arrangement with a resistive element having shaped elements on its surface, such as protrusions or recesses, is used to precisely position measuring probes, minimizing temperature influence and ensuring accurate voltage measurements by eliminating the need for taps on terminal elements, and allowing for redundant measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If voltage taps are positioned on terminal elements to measure voltage drop, then measurement can be performed, but temperature dependence of terminal material significantly influences measurement signal
Solution Approach 1:
The invention extracts the voltage measurement function from the terminal elements and relocates it to the resistive element itself by creating tapped connections at specific positions on the resistive element. This separation removes the temperature-dependent terminal material from the measurement circuit, eliminating its harmful influence on measurement accuracy.
Solution Approach 2:
The tapped connections serve as intermediary elements that provide direct electrical access to the resistive element at predetermined positions. These intermediaries enable voltage measurement without requiring contact with the terminal elements, thus mediating between the measurement need and the temperature-stable resistive element.
2Measurement precision
If voltage taps are positioned very precisely on the resistor to eliminate temperature influence, then measurement accuracy is improved, but manufacturing complexity increases due to precise positioning requirements
Solution Approach 1:
The tapped connections are integrated into the resistive element during its manufacturing process, before the resistive element is assembled into the final resistor arrangement. This preliminary formation of measurement taps eliminates the need for subsequent precise positioning operations, reducing manufacturing complexity while maintaining measurement accuracy.
Solution Approach 2:
The invention merges the formation of the resistive element and the tapped connections into a single manufacturing process. The tapped connections are created as integral parts of the resistive element during its production, combining two previously separate operations (resistive element fabrication and tap positioning) into one unified process.
3Measurement precision
If the resistive element material has high resistivity for accurate measurement, then measurement sensitivity is improved, but the material selection is limited
Solution Approach 1:
The invention employs composite material structures where the resistive element is made from materials with high resistivity for measurement accuracy, while the terminal elements use highly conductive materials for low-impedance connections. This composite approach allows optimization of each component's material properties for its specific function, expanding overall system versatility.
Solution Approach 2:
The invention applies different material qualities to different parts of the resistor arrangement: the resistive element uses high-resistivity material for measurement sensitivity, while the terminal elements use low-resistivity material for efficient current conduction. This local differentiation of material properties allows each component to be optimized for its specific function.
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 resistor arrangement achieves high measurement accuracy and reliability by precisely positioning measuring probes, reducing temperature-induced errors and enabling consistent resistance values, even with varying resistive element properties.
Implementation Method 1
The composite material is produced from three metal strips by joining the individual metal strips together via a longitudinal seam using an electron beam or laser welding process.
Implementation Method 2
The composite material is produced from three metal strips by joining the individual metal strips together via a longitudinal seam using an electron beam or laser welding process.
Implementation Method 3
An aluminum wire is connected to the silicon rod by ultrasonic welding.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a resistor arrangement (1) comprising at least two terminal elements (21, 22) and at least one strip- or plate-shaped resistor element (3) arranged between the terminal elements (21, 22), wherein the resistor element (3) has a top (31), a bottom (32), and two parallel longitudinal sides (33, 34), and wherein the at least one resistor element (3) is made of a material whose electrical conductivity is lower than the electrical conductivity of the material of the terminal elements (21, 22). The resistor element (3) has at least one shaping element (4) as a positioning aid on at least its top (31) or at least its bottom (32). The invention further relates to methods for manufacturing such a resistor arrangement.