Manganin Shunt With 100A For Single Phase Meter
Products Description
This Manganin Shunt with 100A for Single Phase Meter is a high-precision sampling shunt resistor specifically designed for single-phase smart meters. The core conductive resistor substrate uses standard 6J13 manganese-copper alloy, while the conductive busbars at both ends use high-purity T2 copper strips. Electron beam welding is used to achieve a metallurgical bond between dissimilar metals, and the finished copper terminal area undergoes partial tin plating. It is compatible with 100A-rated current single-phase energy metering circuits.
The E-Beam Welding Manganin Electrical Shunt is developed entirely to meet the long-term stable sampling needs of power grid metering equipment. From material matching, vacuum welding process, plating protection to dimensional consistency, the entire process has been engineered and optimized. It is compatible with traditional electronic meters, IoT smart single-phase metering terminals, and residential new energy storage single-phase power acquisition modules, solving engineering pain points such as excessive temperature drift, weld creep, long-term resistance drift, and terminal oxidation failure that exist in ordinary riveting and brazing shunts.
Core Highlights
1. Vacuum Electron Beam Welding (EBW) for Reliable Dissimilar Metal Connections
The core of the product uses vacuum electron beam welding of 6J13 manganin strips and T2 copper strips. The welding process eliminates the need for traditional brazing filler metals. In a high-vacuum environment, a high-speed electron beam instantly melts the materials, achieving a high-strength metallurgical bond. This is a typical manufacturing solution for EBW Manganin Shunt with for Electronic Meters.
2. Formation of a Stable Transition Alloy Layer
The welding area of the E-Beam Welding Manganin Shunt for Smart Energy Meter forms a manganin-copper transition alloy layer, resulting in a smooth transition in resistivity and thermal expansion properties, reducing interfacial thermal stress concentration, and improving long-term cyclic operation stability.
3. Minimal Heat-Affected Zone
EBW (Electric Electrode Welding) energy concentration and short soldering time maximize the preservation of the original resistive properties of the manganin material, minimizing the impact of localized structural changes on the metering accuracy of the Manganin Shunt for Energy Meter.
4. Localized Tin Plating on Copper
The localized tin plating on the conductive ends of the Resistor Manganese Shunt for Electric Meter improves solderability and oxidation resistance, facilitating subsequent PCB soldering or busbar connection, while also reducing contact resistance variations during long-term service.
Product Details and Features
Soldering Zone Design
The EBW weld seam is located in the transition area between copper and manganin. This area is designed after stamping to be in a non-current density peak region, avoiding maximum thermal and electrical stress on the weld seam and extending the interface life of the Copper Alloy Shunt.
Stress Relief Structure
In the transition area between manganin and copper, the stamping die features a pre-designed micro-arc buffer structure to absorb stress caused by the difference in linear expansion coefficients of the two materials during thermal cycling, preventing micro-cracks in the weld joints of the Fitting Relay for Smart Energy Meter.
Deburring and Passivation
The stamped edges undergo precision deburring and passivation to prevent damage to the plastic housing of the Mangnetic Latching Relay Shunt or scratches to the PCB circuitry during transport and automated assembly.
Manufacturing Advantages
Closed-Loop Control of Welding Parameters: The electron beam welder is equipped with real-time beam current monitoring and vacuum feedback, ensuring traceability of welding process parameters and high batch-to-batch weld quality consistency.
No Filler Material: EBW is a self-fluxing weld, introducing no welding wire or filler metal. The weld composition consists only of the base metal alloy, avoiding foreign metal contamination. As a core process of the Maganin Shunt Resistor shunt, this characteristic ensures weld purity and long-term resistance stability.
High aspect ratio: Electron beam welding achieves an aspect ratio of over 10:1, resulting in aesthetically pleasing butt welds on thin plates with no spatter on the back side, eliminating the need for secondary cleaning. This feature enables the precision structure of the Manganin Shunt for Single Phase, making it particularly suitable for the compact assembly requirements of single-phase energy meters.
Automation compatibility: The welding process is programmable, adaptable to robotic loading and unloading, and suitable for mass production. For products with high consistency requirements, such as Maganin Copper Shunt for Electronics Energy Meter, automated EBW processes effectively control batch-to-batch quality fluctuations, ensuring the stability of the smart meter supply chain.
contact us
If you are currently selecting or verifying the overall reliability of Manganin Shunt with 100A for Single Phase Meter for single-phase smart meters or residential energy storage devices, please feel free to contact us to obtain complete material performance reports and samples for comparative testing. We can also collaborate with our R&D team to provide EBW welding process technical data and customized modification solutions.
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