Shunt Terminals For Magnetic Latching Relay 100A
Products Description
The Shunt Terminal for Magnetic Latching Relay 100A is a high-precision composite metal component integrating conductive connection, current sampling, and structural integration. It is widely used in magnetic latching relays, smart meter relays, power control systems, new energy control modules, and high-reliability current detection devices.
This product is not a traditional single-material copper-stamped part. Instead, it is made by forming a composite strip from copper and manganin alloy using electron beam laser welding, followed by high-precision stamping. Its core advantages lie in simultaneously achieving:
High current conduction capability in the main circuit
Precise and stable current sampling performance
Long-term low-temperature drift characteristics
Miniaturized structural integration capability
High-consistency mass production capability
In magnetic latching relay systems, the shunt terminal not only performs a conductive function but also directly participates in current detection and system control logic. Its stability directly affects relay action judgment, energy management, and overall system reliability.
Technical Features and Manufacturing Advantages: The Allure of Vacuum Electron Beam Welding
Zero-Porosity Weld Control
Electron beam welding is performed in a vacuum environment, avoiding oxidation and impurity ingress. The weld has a high depth-to-width ratio and can withstand frequent mechanical vibrations and current surges.
Precision Stamping
High-precision progressive dies are used to stamp the welded composite strip. We have solved the processing challenges caused by the difference in hardness between manganese, copper, and the plasticity of pure copper, ensuring that the geometric tolerance of the Electrical Meter Shunt is controlled within 0.05 mm.
Precise Resistance Adjustment
Utilizing automated laser resistance adjustment technology (optional), the sampled resistance value of each Manganin Copper Shunt can be controlled within an extremely narrow tolerance range, simplifying the customer's post-calibration process.
Main Functions: A Loyal Guardian of the 100A High-Current Circuit
Ultra-Low Power Main Circuit Conduction
The Copper Manganin Shunt area provides an extremely low-impedance current path, capable of withstanding 100A-rated current and thousands of amperes of short-circuit current without melting, ensuring uninterrupted power flow in the relay contact circuit.
Temperature-Drift-Resistant Precision Current Sensing
The manganese-copper area converts ampere-level current into millivolt-level voltage signals at an extremely stable ratio, transmitting them to the control IC unaffected by drastic fluctuations in ambient temperature, enabling precise overload and short-circuit protection triggering of the relay.
Dual-Terminal Mechanical Anchoring
As the lead-out terminal of the magnetic latching relay, its high-strength copper area is responsible for bolting or crimping to the external power grid or PCB board, providing reliable mechanical support and power transmission.
Detailed Demonstration: The Truth Lies in the Microscopic Details
| Smooth Metallographic Transition of Welds | After stamping, the laser-welded surface exhibits micron-level smoothness, without obvious weld scars or collapse. This is crucial for components that will subsequently serve as sliding contact surfaces or precision assembly surfaces. |
| Burry-Free Punching of Sampling Slits | The slits of the manganese-copper isolation voltage sampling pins utilize micro-gap punching technology, resulting in extremely high slit wall perpendicularity and eliminating microscopic burr bridging, completely eradicating the potential short-circuit risk in signal sampling. |
| Chamfering and Deburring of Terminal Crimping Areas | The areas where Electric Current Measure Manganin Shunts are inserted into external wiring harnesses or PCB holes undergo special deburring and chamfering treatment to ensure smooth insertion and removal without scratching the plating of the corresponding connectors. |
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We not only provide standardized Magnetic Shunt Customizeds, but also offer integrated engineering and manufacturing support based on customers' relay structures, current sampling requirements, and automated assembly solutions. This support ranges from composite strip development and electron beam laser welding to precision stamping, helping customers achieve more stable mass production and long-term, reliable operation.
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