Current Sensor Mounting Sleeve Press Fit Design
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Solution Overview
Problem
The existing mounting devices for current conductors in current sensors are expensive and require multiple steps for precise and clean installation, making the process time-consuming and inefficient.
Innovation Solution
A device comprising two sleeve-shaped half-shells that form a sleeve with a press fit, where the inner diameter is slightly smaller than the conductor and the outer diameter is slightly larger than the current sensor opening, supported by centering pins and fastening webs, allowing for quick and secure attachment of the conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mounting device with lips and hinge-connected half-shells is used, then the conductor can be positioned in the opening, but the assembly process becomes expensive and time-consuming due to multiple fastening steps
Solution Approach 1:
The mounting device is divided into two separate functional elements: a sleeve that receives the conductor and a mounting element that secures the sleeve in the opening. This segmentation allows each element to be optimized independently and simplifies the assembly process by reducing the number of steps required
Solution Approach 2:
The complex lip mechanism and hinge-connected half-shells from the prior art are extracted and replaced with a simpler integrated sleeve-m mounting element combination. The essential function of securing the conductor is maintained while removing unnecessary complexity that slowed down assembly
2Manufacturing precision
If multiple fastening steps are used to secure the mounting device, then precise and clean mounting is achieved, but the assembly process becomes expensive and time-consuming
Solution Approach 1:
The sleeve and mounting element are designed to work together as an integrated system. The sleeve receives the conductor while the mounting element simultaneously secures the sleeve in the opening through a single press-fit operation, combining multiple functions into one assembly step
Solution Approach 2:
The sleeve is designed with specific dimensional tolerances (inner diameter slightly smaller than conductor outer diameter, outer diameter slightly larger than opening inner diameter) to create an interference fit. This localized precision in critical dimensions achieves secure mounting without requiring multiple fastening steps
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
Enables fast, precise, and secure installation of current conductors in current sensors with a single device adaptable to various conductor diameters, reducing assembly time and costs while ensuring a firm attachment.
Implementation Method 1
the inner diameter of which is (slightly) smaller than the outer diameter of the current conductor accommodated in the sleeve and the outer diameter of which is (slightly) larger than the inner diameter to form a press fit of the sleeve in the current sensor the opening of the current sensor is formed
Data Source
Figure 1
Figure 2
AI summary
A device (200) for mounting at least one current conductor (300) in an opening (110) of a current sensor (100) is characterized by two sleeve-shaped half-shells (210, 220) that can be attached to one another to form a sleeve, the inner diameter (d) of which is slightly smaller than the outer diameter (310) of the current conductor (300) received in the sleeve and the outer diameter (D) of which is slightly larger than the inner diameter of the opening (110) of the current sensor to form a press fit of the sleeve in the current sensor (100).