Braze Welding Shunt Resistance For Energy Meter
Products Description
The core function of a Braze Welding Shunt Resistance for Energy Meter in an energy meter is to convert the current in the circuit into a measurable, minute voltage signal for precise sampling by the metering chip. To achieve stable current detection, the material's temperature coefficient of resistance (TCR), structural stability, and welding reliability must meet extremely high standards.
This product employs a manganese-copper-copper composite structure design:
The manganese-copper alloy portion, serving as the resistance measurement area, possesses an extremely low temperature coefficient of resistance and excellent resistance stability, ensuring a stable and reliable current sampling signal.
The copper conductor portion, serving as the current conduction path, exhibits excellent conductivity and low resistance loss, capable of carrying a large current.
The two materials are bonded together using electron beam laser welding technology to form a composite strip, which is then precision stamped to form the final shunt structure. This structure significantly reduces contact resistance and energy loss while ensuring accurate resistance values.
Technical Features: The Core Value of Electron Beam Laser Welding (EBW)
Extremely narrow and deep weld
High-energy electron beams instantly melt the metal in a vacuum, resulting in an extremely narrow weld zone and a negligible heat-affected zone (HAZ), preserving the original, precise resistive characteristics of manganese copper.
Zero-impurity connection
Because the Manganin Shunt Resistor is completed in a vacuum environment, oxides, bubbles, and flux residues are eliminated, ensuring the electrical continuity and extremely high mechanical strength of the weld interface.
Dense metallographic structure
The uniform metallographic structure at the weld joint can withstand the mechanical vibration and thermal shock generated by the frequent operation of the magnetic latching relay.
Main Functions and Application Advantages
Electricity Meters (Smart Meters/Industrial Meters)
The Electric Current Measure Manganin Shunt is the core component for current sampling in electricity meters. Its long-term stability directly affects the metering accuracy and calibration cycle. Our electron beam-welded composite shunt, with its interface drift-free characteristics, meets the stringent requirements for long-term stability in electricity meters, and is especially suitable for three-phase industrial meters requiring high-precision metering.
Magnetic Latching Relays
In magnetic latching relays, the Micro Ohm Manganin Welding Shunt Resistor is typically used for overcurrent detection or status feedback. The compact internal space of the relay places high demands on the geometry and installation method of the shunt. Our customized stamped components can precisely match the internal layout of the relay while providing a reliable current sampling signal.
Charging Piles and Electric Vehicle Charging Modules
In AC charging piles or on-board chargers, the Magnetic Shunt Customized is used to detect the charging current, achieving overload protection and power metering. Under high current conditions, temperature rise control of the shunt is particularly critical. The high conductivity of the copper terminals effectively reduces the overall temperature rise, ensuring the thermal safety of the charging system.
Industrial Power Supplies and Inverters
In industrial equipment requiring real-time current monitoring, shunts are the preferred solution for current sampling due to their simplicity, reliability, and lack of auxiliary power requirements. Our composite structure shunts offer flexible installation options and excellent vibration resistance while maintaining high accuracy.
Design Advantages – An Integrated Solution Specifically Optimized for Current Shunt of Magnetic Latching Relays
The Bar Shape Shunt Resistor for this energy meter was designed from the outset with the actual operating conditions of magnetic latching relays in mind: the length and cross-section of the manganese copper resistor section were optimized through finite element thermo-electric simulation to ensure uniform current shunting and minimize self-heating; the bending angle and positioning hole positions of the copper terminals were matched to the relay's operating trajectory through dynamic analysis to avoid stress concentration during assembly. Compared to traditional single-material shunts, this product achieves integrated resistance and conductivity through laser welding, eliminating the need for additional welding or adjustment by the customer. Direct crimping installation significantly reduces assembly deviations and potential failure points, improving overall metering accuracy and switch lifespan.
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Leveraging our professional laser welding composite engineering design team and rigorous metallurgical interface control process system, we provide you with the most reliable magnetic latching relay current Spot Welding for Manganin Shunt Resistor solutions. Please click the "Inquire Now" button below to submit your electricity meter or relay technical parameters, and we will deliver customized engineering samples and complete technical support within 24 hours.
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