Products Description
The EBW Manganin Shunt for Relay is a functional composite metal component manufactured through a process involving electron beam welding (EBW) technology-which achieves a metallurgical bond between high-resistivity Manganin alloy and high-conductivity oxygen-free copper at the strip level-followed by precision stamping. It is specifically designed for integration into switching devices-such as latching relays-that require real-time, precise monitoring of load current. Its core function is to convert the high current flowing through the main circuit into a minute, millivolt-level voltage signal-scaled with precise proportionality and characterized by extremely low added resistance and thermal electromotive force-thereby enabling non-contact, in-line current monitoring and protection.
Manufacturing Advantages
Continuous Strip Welding Technology
We utilize imported vacuum electron beam welding equipment for Manganin Shunt for Single Phase Latching Relay to achieve continuous, full-roll welding of manganese-copper and pure copper strips. This process ensures exceptional weld seam consistency and effectively prevents the compositional segregation issues often associated with discrete-piece welding.
High-Precision Progressive Die Stamping
Supported by high-tonnage precision stamping lines, we ensure that the effective length tolerance of the manganese-copper resistive section is controlled at the micron level. This guarantees resistance value consistency at the source for Electrical Meter Shunt (achieving resistance tolerances ranging from ±1% to ±5%).
Customized Structural Adaptation
Beyond offering standard Relay Resistor Shunt, we are capable of designing custom-shaped bends, specific hole patterns, or multi-point welded terminals, tailored precisely to fit the internal spatial structure of magnetic latching relays.
Design Advantages
| Modular Size Series | Covers the commonly used resistance range of 50 μΩ to 500 μΩ, with physical dimensions of Manganin Copper Shunt compatible with mainstream relay structures, thereby reducing the number of molds required by relay manufacturers. |
| Configurable Sensing Terminals | The width, pitch, and protrusion length of the sensing Copper Manganin Shunt can be customized to align with the relay's PCB layout, accommodating the pin configurations of various MCUs or metering chips. |
| Integrated Stress Relief Features |
The Energy Meter Shunt's bending zones feature curved transitions or dedicated stress relief slots; this design prevents residual stresses induced during the stamping process-from gradually releasing during thermal cycling, thereby eliminating resistance drift. |
Frequently Asked Questions
Q1: What material options are available for the Relay Resistor Shunt?
A1: We offer a bimetallic composite structure consisting of CuMn12Ni4 Manganin and T2 electrolytic copper. Other alloy combinations can also be customized according to specific requirements.
Q2: What are the advantages of Electron Beam Welding for Manganin Copper Shunt compared to standard resistance welding?
A2: Electron Beam Welding is performed in a high-vacuum environment, characterized by extremely high energy density and highly concentrated heat input. It enables a true metallurgical bond between the copper and Manganin materials-yielding a bond strength far superior to that of standard resistance welding or brazing-without introducing any third-party solder impurities. This ensures exceptionally low contact resistance and long-term stability during operation.
Q3: What level of resistance precision can be achieved?
A3: Our standard Copper Manganin Shunt features a resistance tolerance of ±5%; however, higher precision grades of ±1% or ±2% can be customized upon request.
contact us
If you have requirements for EBW Manganin Shunts for relays, need to consult on technical specifications, or wish to obtain samples for validation and a quotation, please feel free to contact our professional team at any time. We will provide tailored services and technical support based on your specific application scenarios.
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