Modular Bus Bar Current Sensor for Testability
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Solution Overview
Problem
Integrated bus bar electric current sensors with resin molding prevent the insertion of test bus bars, making it impossible to check the sensor characteristics using a general checker.
Innovation Solution
A bus bar assemble type electric current sensor design featuring a sensing module with resin molding and a bus bar module with a casing, including temporarily-fixing and fully-fixing portions that allow independent handling and easy integration, enabling the insertion of test bus bars for characterization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric current sensor is integrated with a bus bar by resin molding, then workability at installation and durability such as vibration resistance are improved, but it becomes impossible to insert test bus bars for checking sensor characteristics
Solution Approach 1:
The electric current sensor is divided into two separate modules: a sensing module containing the sensing element and resin molding, and a bus bar module containing the bus bar. This segmentation allows the sensing module to be handled independently for characterization testing, while the bus bar module provides the actual current-carrying component. The modules can be temporarily separated during inspection and then integrated through fixing portions, resolving the contradiction between integrated durability and testability.
2Ease of manufacture
If the electric current sensor is integrated with a bus bar by resin molding, then workability at installation is improved, but independent handling of sensing element for testing is prevented
Solution Approach 1:
The fixing portions are designed to provide dynamic adjustability: they allow the sensing module and bus bar module to be temporarily fixed together during assembly for easy installation, but can be separated when testing is required. This dynamic capability enables the system to switch between integrated state (for installation and operation) and separated state (for testing), resolving the contradiction between ease of manufacture and ease of operation.
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
Facilitates easy checking of sensing element characteristics by allowing independent handling and integration of the sensing and bus bar modules, improving workability and durability during installation.
Implementation Method 1
an electric current sensor measures, by using a Hall element or the like, an electric current flowing through a bus bar(s)
Data Source
AI summary
A bus bar assemble type electric current sensor includes a sensing module that has a resin molding and a sensing element provided in the resin molding, and a bus bar module that has a casing and a bus bar accommodated in the casing and disposed in the vicinity of the sensing element. A temporarily-fixing portion that temporarily fixes the sensing module and the bus bar module separably is provided on at least one of the sensing module and the bus bar module. A fully-fixing portion that integrally fixes the sensing module and the bus bar module with each other is provided on each of the sensing module and the bus bar module.