Products introduction
In China's high-end electronic component manufacturing sector, magnetic latching relays are core devices in scenarios such as power metering and industrial control, and their current sampling accuracy directly determines the reliability of equipment operation. Prepayment Meter Shunt stamped parts/assemblies, as key supporting components for magnetic latching relays, leverage the composite structure of copper and manganese-copper alloys and precision manufacturing processes to become a core support for ensuring the accuracy of current detection, forming a complete industrial system from material research and development, process innovation, to end-user applications.
Product Core Definition and Structural Characteristics
Cable Wire Shunt Resistors are precision current sampling elements specifically designed for magnetic latching relays. The core structure uses a composite strip formed by electron beam or laser welding of copper and manganese-copper alloys, which is then stamped. Manganese-copper alloy, composed of copper, manganese, and nickel, possesses an extremely low temperature coefficient of resistance, high resistivity, and excellent long-term stability. It achieves precise resistance values in a small volume, and its oxidation and corrosion resistance make it suitable for harsh working environments. Pure copper, on the other hand, boasts high electrical and thermal conductivity, which, when used as electrodes, reduces contact resistance and ensures efficient current transmission.
Primary Wire Manganin Shunts are categorized by structure into unipolar and bipolar types, and by accuracy class into 0.1, 0.2, and 0.5 grades. Resistance values are typically in the milliohm range, capable of generating a stable voltage drop while carrying currents from tens to hundreds of amperes. High-precision sampling is achieved by using Ohm's law (U=I×R) to inversely calculate the main circuit current. Some high-end products also integrate sampling bumps and anti-interference magnetic rings to further enhance electromagnetic interference resistance.
Key Manufacturing Processes and Technical Requirements
Composite Strip Welding Process: The core technology employed in the Cable Wire Shunt Resistor is electron beam welding or red-blue composite laser welding, both of which enable efficient and reliable connections between pure copper and manganese-copper alloys. Electron beam welding uses a high-energy electron beam in a vacuum environment to act on the weld seam, forming a dense bonding layer. Laser welding uses a composite beam of near-infrared and blue lasers, achieving welding speeds of 40-60 mm/s and controlling the spot diameter to 0.5-1 mm. This reduces welding spatter and material overheating, ensuring consistent weld quality. Before welding, the strip surface must be cleaned and degreased to ensure the surfaces to be welded are on the same horizontal plane. During welding, the beam tilt angle should be no less than 7° to form a through-layer bonding layer.
Stamping and Subsequent Processing: The welded composite strip is formed through a precision stamping process. High-precision stamping equipment and customized molds are required to ensure that the product's dimensional tolerance is controlled within ±0.01 mm, meeting the assembly accuracy requirements of magnetic latching relays. After stamping, some Primary Wire Manganin Shunts require spot welding to connect the sampling cable to preset sampling bumps. Some products are also equipped with alternating magnetic field shielding to prevent external magnetic fields from interfering with the sampling signal and improve measurement accuracy.
our Products
We are proud to introduce our star product-the Terminal Block Manganin Shunt. This product integrates advanced electron beam laser welding technology and high-precision stamping processes, ensuring that every step from materials to finished product reaches industry-leading standards.
Our Copper Alloy Shunts utilize high-quality manganese-copper alloy and pure copper materials, achieving a perfect combination of copper and manganese-copper through precise welding processes. This unique structural design not only guarantees the high precision and stability of the shunt but also significantly reduces resistance and temperature rise, making it outstanding in high-current detection and control.
Furthermore, our products undergo rigorous surface treatment to enhance corrosion resistance and service life. Whether in magnetic latching relays or other high-precision current sensing equipment, our Prepayment Meter Shunts provide superior performance and reliable assurance.
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