Shunt Busbar Current Sensor Assembly Without Bolts or Nuts
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Solution Overview
Problem
The shunt-type current sensor with a shunt resistor-integrated busbar has high manufacturing costs and complex assembly due to the use of bolts and nuts for fixing the busbar to a circuit board.
Innovation Solution
A current sensor design that fixes the busbar and circuit board using soldered fixing portions, with electrical connection portions arranged between second portions of the fixing portions, allowing for a simple and inexpensive configuration without bolts or nuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolts and nuts are used to fix the busbar to the circuit board, then the connection strength is improved, but the manufacturing cost increases and assembly becomes complicated
Solution Approach 1:
The fixing portion integrates both the mechanical fixing function and the electrical connection function into a single structure. The fixing portion includes a first portion that fixes the busbar to the circuit board and a second portion that provides electrical connection, eliminating the need for separate bolts, nuts, and wire connections. This merging reduces assembly complexity while maintaining connection strength.
Solution Approach 2:
The fixing portion serves multiple functions simultaneously: it mechanically secures the busbar to the circuit board (fixing function) and provides electrical connection between the busbar and circuit board (connection function). This multi-functionality eliminates the need for separate components, reducing both assembly complexity and manufacturing cost.
2Strength
If bolts and nuts are used to fix the busbar to the circuit board, then the connection strength is improved, but the manufacturing cost increases
Solution Approach 1:
The fixing portion combines fixing and electrical connection functions into one integrated component, eliminating the need for multiple separate parts (bolts, nuts, wires). This reduction in part count lowers manufacturing costs while maintaining adequate connection strength through the unified structure.
Solution Approach 2:
The fixing portion performs both mechanical fixing and electrical connection functions simultaneously, replacing multiple specialized components with a single multi-functional element. This reduces material costs, assembly costs, and manufacturing complexity.
3Reliability
If electrical connection portions are arranged between the second portions of the fixing portions, then the reliability of electrical connection is improved, but the device complexity increases
Solution Approach 1:
The electrical connection portions are integrated within the structure of the fixing portions, specifically arranged between the second portions. This merging of connection elements into the fixing structure provides reliable electrical connection without adding separate connection components, thus avoiding increased structural complexity.
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 design ensures reliable electrical connectivity with reduced chances of detachment, enabling cost-effective assembly and early detection of potential connection failures.
Implementation Method 1
fixes the busbar and circuit board using soldered fixing portions
Data Source
AI summary
A current sensor includes a circuit board, a shunt resistor-integrated busbar including two busbar portions and a shunt resistor portion connected between the two busbar portions, electrical connection portions for electrically connecting conductive traces arranged on the circuit board and the busbar portions, and a fixing portion for fixing the circuit board to the shunt resistor-integrated busbar, wherein where a longitudinal direction of the shunt resistor-integrated busbar is defined as an X axis direction, and a width direction of the shunt resistor-integrated busbar is defined as a Y axis direction, the fixing portion includes, on each of the two busbar portions, a first portion extending in the Y axis direction, and a pair of second portions extending toward the shunt resistor portion from both ends, in the Y axis direction, of the first portion, and wherein the electrical connection portions are arranged between the second portions constituting the pair.