Magnetic Current Sensor Pin Locking for Heat and Vibration
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Solution Overview
Problem
Existing magnetic current sensors face issues with connection pins that can lead to breakage due to operating temperatures and vibrations, causing unreliable connections in high-power circuit breakers.
Innovation Solution
Implementing connection pins with folded tabs that lock into a housing on the coil, ensuring a robust and reliable mechanical attachment without glue, capable of withstanding high temperatures and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection pins are mounted on the coil by mechanical interference (wedging/clipping), then the mounting is simple to implement, but the connection is unreliable under operating temperatures and vibrations
Solution Approach 1:
The connection pin incorporates a deformable tab that transitions from a straight configuration during assembly to a bent configuration after assembly. The tab is bent against the housing wall to lock the connection pin in place, creating a dynamic adaptation that ensures reliable mechanical interlocking under operating conditions while maintaining simple assembly procedures
2Reliability
If connection pins are reinforced with glue or resin, then the connection reliability is improved, but the solution is problematic from environmental and repeatability points of view
Solution Approach 1:
The invention replaces chemical bonding methods (glue or resin) with a purely mechanical locking mechanism. The deformable tab, when bent against the housing wall, creates a secure mechanical interlock that eliminates the need for chemical adhesives, thereby resolving environmental concerns and improving assembly repeatability while maintaining connection reliability
3Reliability
If tabs are folded against the housing wall to lock the connection pin, then the mounting robustness is improved, but the tabs must not extend across the interior of the coil
Solution Approach 1:
The tab is designed with differentiated functional zones: a bending zone that allows deformation during assembly, a contact zone that engages with the housing wall for locking, and a constrained zone that remains within acceptable geometric boundaries. This local quality differentiation enables the tab to provide robust mechanical locking while maintaining proper spatial configuration that does not interfere with the coil interior
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 provides a practical and effective mounting method for connection pins that maintains electrical connections in high-power circuit breakers, resisting temperatures up to 150°C and vibrations below 8g, without requiring chemical adhesives and simplifying assembly operations.
Implementation Method 1
two tabs (541, 542) projecting from a main body (540) of the connection pin (54), which are folded against a side wall (533.1) of a housing (533) of the coil (53) to receive the main body, this folding being designed to lock the main body in position in the housing and therefore hold the connection pin in place relative to the coil
Data Source
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AI summary
This magnetic current sensor (50) comprises a magnetic circuit (51), an electrical winding (52), an insulating coil (53), and two connecting pins (54, 55) mounted respectively on terminal portions (530, 531) of the coil and connected to ends of the winding. Each connecting pin includes a main body, received in a recess in the coil, and extended along a body axis transverse to a coil axis (X53). Each connecting pin also includes two tabs (541, 542) projecting from a lateral face of the main body, each extending from a junction end with the main body to a free end. At their junction ends, the tabs extend along their respective tab axes, which are parallel and each extend transversely to the coil axis and the body axis.Between their joining end and their free end, the tabs are folded against the same side wall of the housing so as to hold the connecting pin in position.