Integrated Meter Base High Current Switch Design
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Solution Overview
Problem
Existing metrology devices lack a comprehensive integration of measurement and circuit interruption functions, requiring separate external switches or self-contained devices within the meter housing, which is inefficient and material-intensive, especially for residential and business energy supply management.
Innovation Solution
A high current switching circuit is directly integrated into the utility meter base, comprising line and load side terminal assemblies with spring elements and a flux-concentrating core, allowing for efficient current measurement and interruption, with a solenoid actuator and insulative wedge for contact separation, and a switch cover for debris containment and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate external switch or self-contained switch device is used within the meter housing, then circuit interruption function is provided, but device complexity and material usage increase
Solution Approach 1:
The patent combines the measurement function (Hall effect sensor, flux-concentrating core) and circuit interruption function (switch contacts, spring elements, solenoid actuator) into a single integrated meter base structure. The terminal assembly serves dual purposes: it provides electrical connections for current measurement and houses the switch contacts for circuit interruption, eliminating the need for separate external switches or self-contained switch devices.
Solution Approach 2:
The terminal assembly is designed as a multi-functional component that simultaneously performs electrical connection, current measurement support, and circuit interruption. The same structural elements (terminal assembly, flux-concentrating core, spring elements) serve multiple functions: providing electrical pathways for current flow, supporting the magnetic circuit for Hall effect sensing, and forming the switch contacts for service disconnection.
2Reliability
If traditional separate switch mechanisms are used, then circuit interruption is achieved, but material usage and operational complexity increase
Solution Approach 1:
The switch mechanism is merged with the terminal assembly structure. The spring elements serve dual purposes: providing electrical connection and forming one set of switch contacts. The solenoid actuator integrates with the terminal assembly to provide the opening force for circuit interruption, eliminating the need for separate mechanical switch components and reducing overall material usage.
3Device complexity
If integrated high current switching circuit is implemented, then material usage and complexity are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The flux-concentrating core is pre-positioned and secured to the terminal assembly during manufacturing, establishing a fixed geometric relationship with the Hall effect sensor before final assembly. This preliminary positioning ensures that the magnetic flux path is correctly aligned with the Hall cell, maintaining measurement accuracy while simplifying the final assembly process.
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 solution provides a compact, low-material usage design that effectively integrates measurement and circuit interruption functions, reducing material usage and operational complexity while enhancing energy supply management efficiency.
Implementation Method 1
the flux-concentrating core is positioned to focus a flux field onto a Hall cell mounted on the metrology printed circuit board (PCB)
Implementation Method 2
flux-concentrating core for measurement of current flow through the high current circuit elements by focusing a flux field onto a Hall cell
Implementation Method 3
a solenoid actuator and insulative wedge for contact separation
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Disclosed are apparatus and methodology for integrating directly within an electricity meter components corresponding to a high current switch. Line and load terminals forming a portion of the high current switch also correspond to line and load terminals configured for insertion into an electricity meter socket. Plural pairs of spring elements are connected at one end thereof to the meter load terminal while the opposite ends of the spring elements carry contacts configured to cooperate with matching contacts on a conductive support. The conductive support is coupled to the line terminal by a further conductive bar that is configured to support a flux-concentrating core for measurement of current flow through the high current switch. The present subject matter has to do with integrating a service disconnect switch directly into the base of a meter so as to provide a dual functionality component.