Shunt Resistor Terminal Slit Design for Sensing Accuracy
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Solution Overview
Problem
The existing configuration of shunt resistors with separate main bodies and terminal members often results in insufficient sensing accuracy due to current path crossing and increased material loss, especially when detecting large currents in automotive batteries.
Innovation Solution
A shunt resistor configuration where the terminal member is electrically connected to the resistance main body with a slit dividing the circuit connection portion up to the resistance connection portion, preventing current path crossing and maintaining the terminal member as a single part for simplified assembly, enhancing sensing accuracy and reducing material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a four-terminal shunt resistor is formed with a bifurcated terminal shape by forming a slit in the shunt resistance main body, then the terminal can be integrally formed into a shape having two pairs of legs, but this causes material loss and makes it difficult to form complicated shapes when detecting large currents
Solution Approach 1:
The invention divides the terminal into two separate components: a shunt resistance main body and a terminal member. The terminal member is formed separately with the required bifurcated shape and then attached to the main body, avoiding the need to form slits in the main body itself. This segmentation eliminates material loss from main body slitting while still achieving the desired terminal geometry.
Solution Approach 2:
The terminal member is extracted as a separate component from the shunt resistance main body. By taking out the terminal function into a separate attachable component, the invention avoids modifying the main body structure, thereby preventing material loss and enabling flexible terminal design for large current applications.
2Measurement precision
If the circuit connection portion is divided into two parts by a slit, then two circuit connection terminals are formed for voltage measurement, but the slit extending to the resistance connection portion may cause current path crossing and reduce sensing accuracy
Solution Approach 1:
The slit is formed only in the circuit connection portion and not in the resistance connection portion. This partial action approach allows the circuit connection portion to be divided into two separate terminals for voltage measurement, while maintaining the integrity of the resistance connection portion to prevent current path crossing and ensure accurate current sensing.
Solution Approach 2:
The terminal member is designed with different structural qualities in different regions: the circuit connection portion has a slit to create separate voltage measurement terminals, while the resistance connection portion remains continuous to ensure proper current flow. This local differentiation of structural quality resolves the contradiction between measurement precision and reliability.
3Productivity
If the terminal member and shunt resistance main body are formed as separate pieces, then assembly is simplified and material loss is reduced, but sensing accuracy may be insufficient due to contact resistance and potential current path issues
Solution Approach 1:
The terminal member and shunt resistance main body are merged through a specific connection structure where the terminal member is attached to the main body. This merging ensures low contact resistance and proper current flow paths while maintaining the manufacturing advantages of separate component formation, thus achieving both assembly efficiency and measurement precision.
Solution Approach 2:
The terminal member acts as an intermediary component that connects the external circuit to the shunt resistance main body. This intermediary structure is designed to minimize contact resistance and ensure accurate current sensing, bridging the gap between separate component manufacturing and integrated performance.
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
This configuration stabilizes current detection by preventing path crossing and reducing contact resistance, thereby improving sensing accuracy while maintaining a cost-effective and flexible design.
Implementation Method 1
A screw 26 is threaded through the screwing hole 25 into the resistance main body 20, and thereby the terminal member 21 and the resistance main body 20 are fastened to each other, and electrically connected to each other.
Data Source
AI summary
It is an object to provide a configuration with an enhanced sensing accuracy, in which a shunt resistance main body and a terminal member are formed as separate pieces. A shunt resistor includes a resistance main body and a terminal member (21) that is electrically connected to the resistance main body. The terminal member (21) includes a resistance connection portion (23) to be in contact with the resistance main body, and a circuit connection portion (24) provided so as to extend from the resistance connection portion (23). The circuit connection portion (24) is divided into two parts by a slit (27) being formed therein. The slit (27) is formed up to a part of the resistance connection portion (23).