Vehicle Current Sensor Housing and Shunt Attachment
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Solution Overview
Problem
Conventional current sensors in vehicles are prone to breakage due to vulnerable electrical connections and challenging assembly processes, particularly caused by vibrations and misalignment of mounting holes, which can lead to safety risks and inefficiencies in current measurement.
Innovation Solution
The current sensor design includes a housing with aligned holes for secure attachment of the shunt device to the power supply system, featuring a screw-based attaching mechanism that prevents rotation and direct contact with the housing, ensuring stable electrical connections and simplified assembly by integrating the shunt device and printed circuit board within a protective perimeter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrical connection means (pins) are used to connect the shunt device to the printed circuit board, then the current sensor can be assembled, but the electrical connection means is vulnerable to vibration and impact, leading to breakage
Solution Approach 1:
The patent introduces a housing as an intermediary structure that encloses and protects the printed circuit board and shunt device. The housing provides a rigid framework that reduces the impact of vibrations and impacts on the electrical connections, thereby improving reliability without compromising assembly ease
Solution Approach 2:
The housing is designed to beforehand cushion and absorb vibrations and impacts before they can reach the vulnerable electrical connection means. This protective enclosure prevents breakage by distributing mechanical stresses away from the pins and solder joints
2Volume of moving object
If the holes in the end portions are located close to the housing, then the current sensor structure is compact, but the screwdriving tool touches the housing making screwing operation difficult
Solution Approach 1:
The patent divides the attachment function into two separate components: the shunt device with holes for electrical connection, and the housing with holes for mechanical attachment. This segmentation allows the screwing operation to occur at the housing level, away from the shunt device, eliminating tool interference while maintaining compact overall dimensions
3Ease of operation
If the holes are moved away from the housing to prevent tool contact, then the screwing operation is easier, but the torque causes breakage of electrical connection means or elements in contact with them
Solution Approach 1:
The patent separates the electrical connection function (holes in shunt device) from the mechanical attachment function (holes in housing). This allows the screwing operation to be performed at the housing level with proper torque control, while the electrical connections remain protected within the housing, preventing breakage
4Device complexity
If conventional shunt devices are used with holes outside the housing, then the structure is simple, but the screwdriving tool touches the housing making assembly difficult and causing breakage
Solution Approach 1:
The patent merges the shunt device with the housing structure by providing holes in the housing itself for screw attachment. This integration allows the mechanical attachment to occur at the housing level, away from the shunt device components, eliminating tool interference and improving assembly reliability while maintaining structural simplicity
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 design enhances the reliability and durability of current sensors by reducing the likelihood of breakage and simplifying the assembly process, ensuring accurate current measurement and improved safety in high-amperage applications like electric vehicles.
Implementation Method 1
the resistance of a shunt is known precisely and is used to determine the intensity of the electric current flowing through the resistance by measuring the voltage difference across it, using Ohm's law (I = V/R)
Data Source
Figure 1~2
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Figure 5~6
AI summary
A current sensor for motor vehicles comprising: - a printed circuit board (PCB) (10); - a shunt device (20) comprising a first portion (230) comprising a resistive element having a pre-set resistance and a second portion (210, 220) configured to be connected to an electrical conductor (50); and - a housing (30) enclosing at least a portion of the printed circuit board (PCB) (10) and at least a portion of the shunt device (20). The shunt device (20) comprising in the second portion (210, 220) a first hole (21), the housing (30) comprising a second hole (23) and the current sensor further comprising attaching means (40) going through the first and the second hole (21, 23) so as to attach the shunt device (20) to the housing (30).