Shunt Resistor Current Sensor Mechanical Fastening Assembly
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Solution Overview
Problem
Shunt resistance type current sensors have complex assembly processes, high manufacturing costs, and difficulties in rework due to brazing and welding, which affect measurement quality and connector separation.
Innovation Solution
A current sensor design featuring a shunt resistor between bus bars with a fastener for secure alignment, insulating washers for electrical isolation, and soldered sensing wires for stable connections, facilitating easy assembly, cost reduction, and improved rework capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shunt resistor is connected between the input bus bar and the output bus bar through brazing and the sensing wires are welded to the opposite ends of the shunt resistor, then the electrical connection is secure, but the assembly process becomes complex and manufacturing cost increases
Solution Approach 1:
The patent replaces the traditional brazing and welding processes with a mechanical fastening system using a clamp structure. The clamp has a clamp body that holds the shunt resistor and a fastening member that secures the assembly through mechanical pressure instead of thermal bonding, eliminating complex assembly processes while maintaining reliable electrical connection.
Solution Approach 2:
The patent merges the shunt resistor, sensing wires, and connection structure into a single integrated clamp assembly. The sensing wires are embedded within the clamp structure and directly connected to terminal electrodes, combining multiple components into one unit that simplifies assembly while ensuring secure electrical connections.
2Reliability
If the shunt resistor is connected through brazing and sensing wires are welded, then the connection is stable, but the sensor becomes difficult to rework
Solution Approach 1:
The patent segments the current sensor into separable components: the clamp body, shunt resistor, sensing wires, and terminal electrodes. This modular design allows any component to be independently removed or replaced without affecting the entire assembly, enabling easy rework while maintaining stable connections through the fastening mechanism.
Solution Approach 2:
The patent employs a dynamic fastening system with a fastening member that can be easily tightened or loosened. This allows the assembly to be disassembled and reassembled multiple times without permanent damage, providing rework capability while ensuring stable electrical connections when properly assembled.
3Ease of manufacture
If the connector is separated or moved in the traditional design, then assembly is simplified, but measurement quality deteriorates
Solution Approach 1:
The patent nests the sensing wires and terminal electrodes within the clamp structure itself. The terminal electrodes are integrated into the clamp body, and the sensing wires are positioned and secured within the clamp, creating a nested arrangement that prevents separation or movement while maintaining assembly simplicity and ensuring high measurement quality through stable electrical contact.
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 simplifies assembly, reduces manufacturing costs, enhances electrical connection quality, and allows for accurate current sensing while enabling easy rework of incorrectly assembled components.
Implementation Method 1
a fastener coupled through the first bus bar and the second bus bar and the shunt resistor. The first bus bar has a first through-hole, the second bus bar has a second through-hole, and the shunt resistor has a third through-hole. The first through-hole, the second through-hole, and the third through-hole are aligned with one another to allow the fastener to pass through the first to third through-holes.
Implementation Method 2
An insulating washer, which is formed of an insulating material, may be provided between the fastener and the bus bar adjacent to the fastener.
Implementation Method 3
the shunt resistance type current sensor has a shunt resistor, which is a resistor with low resistance, in a circuit to measure electric current and is configured to measure a current value based on a voltage difference between opposite ends of the shunt resistor.
Data Source
AI summary
The present disclosure provides a current sensor including: a shunt resistor provided between a first bus bar and a second bus bar, and a fastener coupled through the first bus bar, the second bus bar, and the shunt resistor. The first bus bar has a first through-hole, the second bus bar has a second through-hole, and the shunt resistor has a third through-hole. The first through-hole, the second through-hole, and the third through-hole are aligned with one another to allow the fastener to pass through the first to third through-holes.