Electricity Measuring Device Rivet Housing Integration
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Solution Overview
Problem
Existing current measurement devices in motor vehicles face challenges in connecting battery terminals inexpensively while absorbing mechanical forces, and require complex installation processes due to the use of screw connections and soldered connections.
Innovation Solution
A rivet is formed on the housing to fasten the terminal, simplifying the electrical/mechanical connection and reducing material and assembly costs, with the housing acting as an insulator and increasing overall stability by penetrating the measuring resistor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections are used to fasten the terminal to the housing, then the mechanical stability is improved, but the material costs and assembly complexity increase
Solution Approach 1:
The patent replaces expensive and complex screw connections with a simple rivet that is formed integrally from the housing material itself. This rivet acts as a disposable fastening element that provides sufficient mechanical stability without requiring additional components or complex assembly steps, thereby reducing both material costs and assembly complexity while maintaining the required strength.
Solution Approach 2:
The housing material itself is utilized to form the rivet, meaning the housing serves its own fastening function. This self-service approach eliminates the need for separate fastening components, reducing device complexity and assembly steps while maintaining mechanical stability through the integral structure.
2Strength
If brazed connections are used to attach the shunt, then the mechanical stability is improved, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent replaces complex brazed mechanical connections with a simpler soldered electrical connection. The rivet provides the mechanical fastening function, while the soldered connection handles the electrical connection, allowing the shunt to be attached more easily without requiring high-temperature brazing processes, thus reducing manufacturing complexity while maintaining adequate strength.
3Object-affected harmful factors
If a housing is used to enclose the sensor device, then the electrical insulation is improved, but the device complexity increases
Solution Approach 1:
The patent merges the housing's structural enclosure function with its electrical insulation function into a single integrated component. The housing simultaneously protects the internal components and provides electrical insulation between the terminal and the measuring resistor, eliminating the need for separate insulation components and reducing overall device complexity while maintaining effective electrical insulation.
4Adaptability or versatility
If multiple separate components are used for fastening, then the adaptability is improved, but the assembly time increases
Solution Approach 1:
The rivet is formed integrally from the housing material during the housing manufacturing process itself, before the final assembly takes place. This preliminary action of creating the fastening element as part of the housing formation eliminates the need for separate fastening steps, reducing assembly time while maintaining the adaptability and mechanical stability that a dedicated fastening component would provide.
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 allows for a reliable and cost-effective connection of battery terminals, absorbing mechanical forces and enhancing device stability, while maintaining a good electrical connection through a soldered link.
Implementation Method 1
A rivet 7 is formed in one piece with the housing 6 and coaxially with the through-holes 8, 9 on a side of the measuring resistor 1 opposite the printed circuit board 2. The rivet 7 penetrates the first through hole 8 and is approximately twice as long as the terminal body 4 is high.
Implementation Method 2
A soldered connection between the first connection and the measuring resistor is easy to produce and ensures a good electrical connection.
Implementation Method 3
the housing acts as an insulator at the relevant points between the first connection and the measuring resistor
Data Source
Figure 1~2
AI summary
The device has a measuring resistor (1), an evaluation electronics, which is electrically connected with the measuring resistor and is enclosed by a housing (6). The housing is manufactured as plastic housing, where the total evaluation electronics together with a part of the measuring resistor is sprayed. A rivet (7) is formed on the housing, with which a connection (4) is fastened on the housing.