Integrated Sensor Mounting for Cast Measurement Devices
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Solution Overview
Problem
Existing measurement device manufacturing processes face challenges in accurately positioning and mechanically/electrically fixing voltage and/or current sensors during molding, with separate elements typically used for mechanical fixation and electrical grounding, leading to complexity and increased production costs.
Innovation Solution
A mechanical element with a central hole and connecting fingers is integrated to serve both as a signal connector holder and grounding connector, ensuring accurate positioning and conductive connection during molding, and providing mechanical stability and electrical grounding during device operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate elements are used for mechanical fixation and electrical grounding, then mechanical stability and electrical connection are ensured, but device complexity and production costs increase
Solution Approach 1:
The patent combines the mechanical fixation function and electrical grounding function into a single integrated element. The connecting element includes both the mechanical structure for positioning the sensor component and the electrical conductor for grounding, eliminating the need for separate fixation components and grounding wires, thus reducing device complexity while maintaining reliability
Solution Approach 2:
The connecting element serves multiple functions simultaneously: it acts as a mechanical fixture for positioning the sensor component during molding, provides electrical connection for grounding, and serves as a structural support element. This multi-functionality reduces the total number of components needed in the system
2Manufacturing precision
If special fixation components are used during molding, then accurate positioning of sensor component is achieved, but manufacturing complexity increases
Solution Approach 1:
The molding fixture is integrated directly into the molding tool itself, combining the positioning function with the molding process. The fixture elements are built-in features of the mold that automatically position the sensor component during injection molding, eliminating the need for separate, complex positioning devices and simplifying the manufacturing process
Solution Approach 2:
The sensor component is pre-positioned using built-in fixture elements within the molding tool before the molding process begins. This preliminary positioning is automatically achieved through the mold design, ensuring accurate placement without requiring additional manual intervention or complex external fixtures during the molding operation
3Reliability
If multiple separate components are used for connector fixation and grounding, then functional requirements are met, but production costs increase
Solution Approach 1:
The patent merges the connector fixation mechanism and grounding connection into a single integrated connecting element. This element includes both the mechanical features for securing the connector and the electrical conductor for grounding, reducing the total component count and assembly steps, thereby lowering production costs while maintaining functional reliability
Solution Approach 2:
The connecting element is designed as a multi-functional component that simultaneously provides mechanical fixation, electrical grounding, and structural support. This universal design eliminates the need for multiple specialized components, reducing material costs, assembly complexity, and production time
Data Source
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AI summary
The invention relates to a measurement device in which voltage and/or a current sensor in a casted measurement device housing, wherein the sensor component is connected with a externally ending output connector by a signal wire, and with a grounding wire to a grounding output connector, where signal connector output and grounding connector output results as the electrical connecting terminal, according to the preamble of claim 1. In order to ensure an accurate positioning of the voltage and/or current measurement device during the molding process, as well as a sure mechanical and electrical fixation of the connecting terminal at the ready measurement device, a further mechanical element (8) is arranged at the electrical connecting terminal, and provided with a central hole (10), through which the signal connector output is feeded, and at least one further connecting finger (8'), which is used as electrical grounding connection as well as a mechanical fixation of the electrical connecting terminal during the moulding process.