Multi-Material Shunt Resistor Layout to Prevent Parallel Drift
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Solution Overview
Problem
Existing resistance arrangements for electric measurement in hybrid and electric vehicles are costly and complex, requiring multiple components and high material effort, which complicates reliable electricity measurement and redundancy for safety-critical applications.
Innovation Solution
A resistance arrangement featuring two resistance elements made from different materials, with a conductive intermediate element between them, arranged in a row. This design ensures that the resistance elements are manufactured from different production batches, reducing the risk of simultaneous errors, and includes only the connection elements with integration capabilities, optimizing material and space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple resistance elements made from the same material are used for redundant measurement, then measurement redundancy is achieved, but parallel drift errors affect both measurements simultaneously
Solution Approach 1:
The patent changes the material parameter of the resistance elements by using at least two different materials (e.g., copper-based and aluminum-based alloys) for the first and second resistance elements. This ensures that environmental influences such as temperature changes affect each resistance element differently, preventing parallel drift and enabling independent error detection while maintaining measurement redundancy.
2Ease of manufacture
If terminal elements and resistance elements are made from different materials, then integration capabilities are optimized, but material complexity increases
Solution Approach 1:
The patent segments the measuring device into distinct functional elements: terminal elements made from highly conductive materials (copper-based) for optimal electrical connection, and resistance elements made from resistive materials (aluminum-based or copper-based alloys) for measurement functionality. This segmentation allows each element to be optimized for its specific function while being manufactured as an integrated piece.
Solution Approach 2:
Different regions of the measuring device are assigned different material properties: the terminal elements have high electrical conductivity for optimal signal transmission, while the resistance elements have appropriate resistance characteristics for accurate current measurement. This local differentiation of material quality optimizes overall device performance.
3Reliability
If resistance elements from different production batches are used, then parallel drift is prevented, but manufacturing complexity increases
Solution Approach 1:
The patent employs composite material construction where the measuring device integrates at least two different materials (copper-based and aluminum-based alloys) in a single integrated piece. This composite approach ensures that resistance elements from different production batches or material sources are combined, preventing parallel drift while maintaining a streamlined manufacturing process through integrated production.
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 enhances the redundancy and reliability of electric measurements by preventing parallel drift of resistance elements, reduces material and production costs, and simplifies the integration of the resistance arrangement into measurement circuits, thereby improving the safety and efficiency of electric vehicle systems.
Implementation Method 1
an electrically conductive intermediate element arranged between the first and second resistor elements and electrically connected to these resistor elements
Implementation Method 2
The current can then be determined from the voltage drop across the shunt resistor
Implementation Method 3
joining the individual metal strips together via a longitudinal seam using an electron beam or laser welding process
Implementation Method 4
joining the individual metal strips together via a longitudinal seam using an electron beam or laser welding process
Data Source
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AI summary
The invention relates to a resistor arrangement (8) comprising: a first electrically conductive terminal element (10) and a second electrically conductive terminal element (11), a first resistor element (12) electrically connected to the first terminal element (10), a second resistor element (13) electrically connected to the second terminal element (11), an electrically conductive intermediate element (14) arranged between the first resistor element (12) and the second resistor element (13) and electrically connected to these resistor elements (12, 13), wherein the terminal elements (10, 11), the resistor elements (12, 13) and the intermediate element (14) are arranged side by side in a row.The connecting elements (10, 11) and the intermediate element (14) on the one hand, and the resistive elements (12, 13) on the other, are made of different materials, the material of the first resistive element (12) differing from the material of the second resistive element (13). The invention further relates to a measuring circuit with the resistive arrangement (8) and a method for producing a ribbon-shaped composite material for the resistive arrangement (8).