A test device for a battery harness

Abstract

The application belongs to the technical field of battery testing, and particularly relates to a testing device for a battery wire harness, which comprises a rack, a fixed base plate and a movable base plate arranged on the rack, the fixed base plate is fixed on the rack, clamping mechanisms are respectively arranged on the fixed base plate and the movable base plate, the two clamping mechanisms are respectively used for clamping two ends of the fixed wire harness, a sliding seat is slidably connected to a cross beam on the top of the rack, the movable base plate is movably arranged on the sliding seat, an electric push rod is further arranged on the rack, an output shaft of the electric push rod is fixedly connected with the sliding seat, at least one touch rod is further fixed to the front end face of the movable base plate, a guide block corresponding to the touch rod is fixed to the top of the rack, and the side of the guide block facing the front end of the touch rod is a slope. The touch rod is matched with the slope of the guide block, the first spring is used for connecting the movable base plate and the sliding seat, and thus the movable base plate can generate a linear pulling force and then a lateral pulling force during movement, so that the real force situation is simulated.

Description

Technical Field

[0001] This invention relates to the field of battery testing technology, and more particularly to a testing device for battery harnesses. Background Technology

[0002] In the context of the rapid development of the new energy industry, especially the electric vehicle industry, the performance and safety of battery packs are of paramount importance. As a key connector for power transmission and signal acquisition within the battery pack, the mechanical reliability of the battery harness directly affects the stability of the entire battery system. During actual vehicle operation, the battery harness is not only subjected to linear tensile forces caused by vehicle vibration, but also to complex lateral tensile or deflection forces due to the harness's fixed path, bending, and relative movement with other components.

[0003] However, most wire harness testing devices currently on the market have limited functionality, only capable of performing tensile tests on wire harnesses along a single axis. They cannot simulate the complex stress states experienced by wire harnesses under real-world working conditions, leading to discrepancies between test data and actual conditions, making it difficult to accurately assess the durability and reliability of wire harnesses. Therefore, developing a testing device capable of simulating the real-world stress environment of wire harnesses has become an urgent technical problem to be solved in this field. Summary of the Invention

[0004] Based on the technical problems existing in the prior art, the present invention proposes a testing device for battery harnesses.

[0005] This invention proposes a testing device for battery wiring harnesses, comprising a frame on which a fixed base plate and a movable base plate are mounted. The fixed base plate is fixed to the frame, and the fixed base plate and the movable base plate have the same structure and are symmetrically distributed. Clamping mechanisms are respectively installed on the fixed base plate and the movable base plate, and the two clamping mechanisms are used to clamp and fix the two ends of the wiring harness. A slide block is slidably connected to the crossbeam at the top of the frame, and the movable base plate is movably mounted on the slide block. An electric push rod is also installed on the frame, and the output shaft of the electric push rod is fixedly connected to the slide block. At least one contact rod is also fixed to the front end face of the movable base plate. A guide block corresponding to the contact rod is fixed to the top of the frame, and the side of the guide block facing the front end of the contact rod is inclined.

[0006] Preferably, multiple first springs are fixed on the left and right sides of the slide block, and two symmetrically distributed spring fixing seats are provided at the bottom of the movable base plate, with the other end of the first spring fixed on the corresponding spring fixing seat.

[0007] Preferably, the clamping mechanism includes a main shaft, which is mounted on a fixed base plate via two bearing seats. A crank is fixed to one end of the main shaft. Multiple evenly distributed gears are fixedly sleeved on the main shaft. A rack is meshed with the lower part of the gears. A guide post is fixed to the inner end of the rack. The inner end of the guide post passes through the fixed base plate and is fixed to an upper clamping block. A second spring is sleeved on the guide post. The two ends of the second spring are fixedly connected to the upper clamping block and the fixed base plate, respectively. A lower clamping block is fixed to the fixed base plate below the upper clamping block. The opposite sides of the lower clamping block and the upper clamping block are both inclined surfaces. Arc-shaped grooves are provided on the two inclined surfaces. The main shaft is also connected to a locking assembly.

[0008] Preferably, the locking assembly includes a ratchet, which is fixedly sleeved on the end of the main shaft. A mounting base is fixed on the fixed base plate, and an L-bar is rotatably connected to the mounting base. The upper surface of the L-bar is provided with ratchet teeth that cooperate with the ratchet. The free end of the L-bar presses down on the arc-shaped elastic strip, and at least one end of the elastic strip is fixed on the fixed base plate.

[0009] Preferably, the front end of the contact rod is a bevel.

[0010] Preferably, the front end of the contact rod is an arc surface.

[0011] Preferably, a roller is installed at the front end of the contact rod.

[0012] Preferably, there are multiple grooves on both the upper and lower clamping blocks, and they are arranged in a one-to-one correspondence.

[0013] Preferably, the second spring is a tension spring.

[0014] Preferably, the stroke of the electric actuator is greater than the initial distance between the tip of the actuator and the inclined surface of the guide block.

[0015] Compared with the prior art, the present invention provides a testing device for battery wiring harnesses, which has the following advantages: 1. By setting a contact rod and a guide block with an inclined surface, and cooperating to movably mount the movable base on the slide, the movable base first performs a linear motion to apply axial tension to the wire harness when driven forward by the electric push rod. When the contact rod contacts the inclined surface of the guide block, the movable base is laterally guided, thereby applying lateral tension to the wire harness. This realizes the composite tension test of the wire harness in one test stroke, which more realistically simulates the actual working conditions.

[0016] 2. By setting multiple first springs between the slide and the spring fixing seat of the movable base, the elastic deformation of the springs provides a restoring force and a certain buffer for the lateral movement of the movable base, making the entire lateral offset process smooth and controllable. After the test is completed, the first springs can help the movable base automatically return to the center, which is convenient for the next test.

[0017] 3. By setting an upper clamping block driven by a gear and rack and a fixed lower clamping block, when the crank is turned, the gear drives the rack and rack to move the upper clamping block towards the lower clamping block. The arc-shaped wire groove on the opposite surface of the two clamps firmly clamps the end of the wire harness. This structure is labor-saving to operate and can clamp multiple wire harnesses at the same time, which greatly improves the testing efficiency.

[0018] 4. By setting up a locking assembly consisting of a ratchet, an L-bar, and an elastic bar, after the crank handle is rotated to clamp the wire harness, the ratchet is locked by the ratchet teeth on the upper surface of the L-bar. This effectively prevents the spindle from rotating in the opposite direction due to vibration or the rebound force of the second spring, ensuring the durability and stability of the clamping force and preventing the wire harness from coming loose during testing.

[0019] 5. By setting a bevel, arc, or roller at the front end of the contact rod, the impact and friction when the contact rod initially contacts the bevel of the guide block are reduced, making the lateral offset process of the moving plate smoother and more efficient, reducing component wear and extending the equipment life. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the first angle structure of the present invention; Figure 2 This is a schematic diagram of the second angle structure of the present invention; Figure 3 For the present invention Figure 1 A magnified structural diagram at point A; Figure 4 This is a schematic diagram of the bottom structure of the movable substrate of the present invention; Figure 5 This is a schematic diagram of the structure of the wire harness of the present invention, which is fixed between a fixed substrate and a movable substrate. Figure 6 This is a schematic diagram of the clamping mechanism of the present invention; Figure 7 For the present invention Figure 5 A magnified structural diagram at point B.

[0021] In the diagram: 1. Frame; 101. Crossbeam; 2. Fixed base plate; 3. Movable base plate; 301. Spring fixing seat; 4. Electric push rod; 5. Slide; 6. First spring; 7. Contact rod; 8. Guide block; 9. Bearing seat; 10. Main shaft; 11. Gear; 12. Rack; 13. Guide post; 14. Upper clamping block; 15. Lower clamping block; 16. Wire groove; 17. Second spring; 18. Crank handle; 19. Mounting seat; 20. L-bar; 21. Elastic strip; 22. Ratchet. Detailed Implementation

[0022] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0023] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0024] Reference Figures 1-7 A testing device for battery wiring harnesses includes a frame 1 as an integral support structure. At least one crossbeam 101 is mounted on the top of the frame 1, preferably oriented in a front-to-back direction. Two base plates for fixing cable ends are mainly mounted on the frame 1: a fixed base plate 2 and a movable base plate 3. The fixed base plate 2 is fixedly mounted on the frame 1 by bolts or welding, and its position is relatively fixed. The movable base plate 3 is designed to move relative to the frame 1. Structurally, the fixed base plate 2 and the movable base plate 3 have identical main structures and are symmetrically distributed on the frame 1. For example, the fixed base plate 2 can be located at the rear of the frame 1, and the movable base plate 3 at the front of the frame 1, facing each other. Clamping mechanisms for holding and fixing the ends of the battery wiring harness are respectively mounted on the fixed base plate 2 and the movable base plate 3. The two clamping mechanisms are responsible for clamping both ends of the same battery wiring harness to be tested, thereby placing the wiring harness between the fixed base plate 2 and the movable base plate 3 with a certain initial tension or slack state.

[0025] Furthermore, to enable the movement of the movable base plate 3, a slide block 5 is slidably connected to the crossbeam 101 at the top of the frame 1. Specifically, a slide rail along the front-to-back direction can be provided on the crossbeam 101, and a slider cooperating with the slide rail is provided at the bottom of the slide block 5, allowing the slide block 5 to slide smoothly back and forth along the direction of the crossbeam 101. The movable base plate 3 itself is not directly fixed to the slide block 5, but is movably mounted on the slide block 5. This movable mounting allows the movable base plate 3 to move laterally (e.g., left and right) relative to the slide block 5 within a certain range. To achieve this movable connection and provide a restoring force, multiple first springs 6 are fixed on the left and right sides of the slide block 5, respectively. Correspondingly, two symmetrically distributed spring fixing seats 301 are provided at the bottom of the movable base plate 3, and the other end of each first spring 6 (i.e., the end away from the slide block 5) is fixed to these spring fixing seats 301. In this way, the movable base plate 3 is like being "suspended" on the slide block 5 by a set of symmetrical springs. When subjected to lateral force, it can compress the spring on one side and stretch the spring on the other side, thereby causing lateral displacement. When the lateral force disappears, the elastic force of the spring will reset it.

[0026] An electric push rod 4, which provides driving force, is also installed on the frame 1. The housing of the electric push rod 4 is fixed to the frame 1, and its output shaft is fixedly connected to the rear or side of the slide 5. When the electric push rod 4 is working, its output shaft extends and retracts, which drives the slide 5 together with the movable base plate 3 mounted on it to make linear reciprocating motion along the direction of the crossbeam 101.

[0027] Furthermore, one of the core improvements of this invention lies in the provision of a guiding structure for generating lateral force. Specifically, at least one contact rod 7 is fixed on the front end face of the movable base plate 3 (i.e., the end face facing the opposite direction to the fixed base plate 2). The contact rod 7 extends outward from the front end face of the movable base plate 3. Simultaneously, at the top of the frame 1, corresponding to the contact rod 7, a guide block 8 is fixed. The side of the guide block 8 facing the front end of the contact rod 7 is designed as a slope. This slope can be a flat surface or a slightly concave or convex arc surface, the purpose of which is to generate a smooth lateral force component when the contact rod 7 contacts it. The front end shape of the contact rod 7 can have various preferred designs, such as a slope, an arc surface, or the installation of a roller. All these designs aim to reduce the impact and friction when the contact rod 7 initially contacts the slope of the guide block 8, making the movement smoother.

[0028] During operation, the operator first securely clamps both ends of the battery harness to be tested using the two clamping mechanisms on the fixed base plate 2 and the movable base plate 3. At this time, the output shaft of the electric push rod 4 should be in its initial position (e.g., retracted). After the test is started, the output shaft of the electric push rod 4 begins to repeatedly extend and retract, pushing the slide 5 and the movable base plate 3 to move back and forth together. In the initial stage of movement, since the front contact rod 7 of the movable base plate 3 has not yet contacted the inclined surface of the guide block 8, the movement trajectory of the movable base plate 3 is entirely guided by the slide 5 and is a straight line. This linear motion generates a purely axial tensile force on the harness clamped between the two base plates, simulating the working condition of the harness when subjected to linear tension.

[0029] As the movable base plate 3 continues to move forward, its front contact rod 7 eventually contacts the inclined surface of the guide block 8 fixed on the frame 1. Since the guide block 8 is stationary, and the contact rod 7 continues to move forward with the movable base plate 3, the inclined surface exerts a lateral force (to the left or right) on the contact rod 7. This lateral force overcomes the elastic force of the first spring 6 on one side, pushing the movable base plate 3 to shift laterally relative to the slide block 5. Since the other end of the movable base plate 3 is fixed to one end of the wiring harness by a clamping mechanism, and the other end of the wiring harness is clamped by a clamping mechanism on the fixed base plate 2, this lateral shifting movement of the movable base plate 3 is equivalent to applying a lateral tensile force or deflection force to the wiring harness. In this way, in a continuous test stroke, the test device first applies a linear tensile force to the wiring harness, and then applies a lateral tensile force, thereby realistically simulating the complex stress state of the battery wiring harness in actual applications (such as when the vehicle turns, vibrates, or there are deviations in component installation). After the test, the output shaft of the electric push rod 4 retracts, causing the slide block 5 and the movable base plate 3 to move backward. The contact rod 7 separates from the guide block 8. Under the reset action of the first spring 6, the movable base plate 3 returns to the center position of the slide block 5, ready for the next test.

[0030] Next, the clamping mechanism used in this embodiment will be described in detail. This clamping mechanism is mounted on the fixed base plate 2. Since the fixed base plate 2 and the movable base plate 3 are structurally symmetrical, the clamping mechanism on the movable base plate 3 has the same structural principle. The clamping mechanism includes a horizontally positioned main shaft 10, which is mounted on the side of the fixed base plate 2 via two bearing seats 9, allowing it to rotate freely. A crank handle 18 for manual operation is fixedly mounted at one end (e.g., the outer end) of the main shaft 10. Multiple evenly distributed gears 11 are fixedly sleeved on the main shaft 10. The number of gears 11 can be determined according to the number of wire harnesses that need to be clamped simultaneously. A rack 12 is meshed directly below each gear 11. The rack 12 can move linearly along a pre-set guide groove on the fixed base plate 2. A guide post 13 is fixedly connected to the inner end of each rack 12 (i.e., the end facing the center of the fixed base plate 2 and the movable base plate 3). The inner end of the guide post 13 passes through a through hole on the fixed base plate 2. Finally, an upper clamping block 14 is fixedly connected to the main shaft 13. A second spring 17 is also sleeved on the guide post 13. The second spring 17 is preferably a tension spring. The two ends of the second spring 17 are fixedly connected to the sides of the upper clamping block 14 and the fixed base plate 2, respectively. Directly below the upper clamping block 14, a lower clamping block 15 is fixed on the fixed base plate 2. The opposite sides of the lower clamping block 15 and the upper clamping block 14 are both inclined surfaces. On these two inclined surfaces, a plurality of arc-shaped wire grooves 16 for accommodating wire harnesses are respectively opened. The wire grooves 16 on the upper clamping block 14 and the wire grooves 16 on the lower clamping block 15 are in one-to-one correspondence. When the two are closed, the wire grooves 16 together form an approximately circular clamping hole. The main shaft 10 is also connected to a locking assembly to prevent it from reversing.

[0031] The specific operating procedure of the clamping mechanism is as follows: First, the operator pinches the upper clamping block 14 with their hand, overcoming the tension of the second spring 17, and pulls it away from the lower clamping block 15, creating sufficient space between them. Then, the ends of one or more battery wire harnesses to be tested are respectively placed into the respective arc-shaped wire grooves 16 on the lower clamping block 15. Next, the upper clamping block 14 is released, and the stretched second spring 17 automatically retracts, causing the upper clamping block 14 to return to its original position, initially pressing it onto the wire harness to achieve pre-compression and prevent the wire harness from falling off. At this time, the operator manually rotates the crank handle 18 clockwise. The crank handle 18 drives the main shaft 10 and all the gears 11 on it to rotate clockwise synchronously. Since the gears 11 mesh with the rack 12, the rotation of the gears 11 will drive the rack 12, together with the guide post 13 and the upper clamping block 14, to move further towards the lower clamping block 15. The inclined surfaces and wire groove 16 on the opposing surfaces of the upper clamping block 14 and the lower clamping block 15 work together to generate a wedge clamping force, firmly clamping and fixing the end of the wire harness between them. When the clamping is tightened to a suitable degree, the crank handle 18 is stopped from being rotated. At this time, the locking assembly connected to the main shaft 10 will automatically lock, preventing the main shaft 10 from reversing due to vibration or the rebound force of the second spring 17, thereby ensuring the long-term stability of the clamping force.

[0032] The locking assembly has the following structure: It includes a ratchet 22, which is fixedly sleeved on the end of the main shaft 10 and located inside the crank handle 18. A mounting base 19 is fixed on the fixed base plate 2. An L-bar 20 is rotatably connected to the mounting base 19 via a pin or other structure. The L-bar 20 can swing at a small angle around its rotation center. The upper surface of the L-bar 20 is machined with ratchet teeth that mesh with the teeth of the ratchet 22. The free end of the L-bar 20 (i.e., the end away from the ratchet teeth) faces downward and presses against an arc-shaped elastic strip 21. The elastic strip 21 has a certain elasticity, and at least one end of it is fixed to the fixed base plate 2, forming an arched elastic support. When the main shaft 10 drives the ratchet 22 to rotate clockwise, the teeth of the ratchet 22 push the ratchet teeth on the upper surface of the L-bar 20, causing the free end of the L-bar 20 to overcome the elastic force of the elastic strip 21 and rotate downward, thus allowing the ratchet 22 to pass smoothly. When rotation stops and there is a tendency to reverse, the elastic bar 21 will push the free end of the L-bar 20 upward, causing the ratchet on its upper surface to tightly engage with the tooth groove of the ratchet 22, thereby preventing the ratchet 22 and the main shaft 10 from rotating in the opposite direction (counterclockwise), achieving one-way locking. When it is necessary to release the clamping mechanism to remove the tested wire harness, simply press the free end of the L-bar 20 downward manually to disengage the ratchet from the ratchet 22, and the rocker handle 18 can be freely rotated in the opposite direction by the second spring 17, automatically releasing the upper clamp 14.

[0033] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A testing device for battery wiring harnesses, comprising a frame (1), characterized in that, The frame (1) is provided with a fixed base plate (2) and a movable base plate (3). The fixed base plate (2) is fixed on the frame (1). The fixed base plate (2) and the movable base plate (3) have the same structure and are symmetrically distributed. The fixed base plate (2) and the movable base plate (3) are respectively equipped with clamping mechanisms. The two clamping mechanisms are used to clamp the two ends of the wire harness respectively. A slide block (5) is slidably connected to the crossbeam (101) at the top of the frame (1). The movable base plate (3) is movably installed on the slide block (5). An electric push rod (4) is also installed on the frame (1). The output shaft of the electric push rod (4) is fixedly connected to the slide block (5). At least one contact rod (7) is also fixed on the front end face of the movable base plate (3). A guide block (8) corresponding to the contact rod (7) is fixed on the top of the frame (1). The side of the guide block (8) facing the front end of the contact rod (7) is an inclined surface.

2. The testing device for battery wiring harnesses according to claim 1, characterized in that, Multiple first springs (6) are fixed on the left and right sides of the slide (5), and two symmetrically distributed spring fixing seats (301) are provided at the bottom of the movable base plate (3). The other end of the first spring (6) is fixed on the corresponding spring fixing seat (301).

3. The testing device for battery wiring harnesses according to claim 1, characterized in that, The clamping mechanism includes a main shaft (10), which is mounted on a fixed base plate (2) via two bearing seats (9). A crank handle (18) is fixed at one end of the main shaft (10). Multiple evenly distributed gears (11) are fixedly sleeved on the main shaft (10). A rack (12) is meshed with the lower part of the gears (11). A guide post (13) is fixed at the inner end of the rack (12). The inner end of the guide post (13) passes through the fixed base plate (2) and is fixed with an upper clamping block (14). A second spring (17) is sleeved on the guide post (13). The two ends of the second spring (17) are fixedly connected to the upper clamping block (14) and the fixed base plate (2) respectively. A lower clamping block (15) is fixed on the fixed base plate (2) below the upper clamping block (14). The opposite sides of the lower clamping block (15) and the upper clamping block (14) are both inclined surfaces. Arc-shaped grooves (16) are provided at the two inclined surfaces respectively. The main shaft (10) is also connected to a locking assembly.

4. The testing device for battery wiring harnesses according to claim 3, characterized in that, The locking assembly includes a ratchet (22), which is fixedly sleeved on the end of the main shaft (10). A mounting base (19) is fixed on the fixed base plate (2). An L-bar (20) is rotatably connected to the mounting base (19). The upper surface of the L-bar (20) is provided with ratchet teeth that cooperate with the ratchet (22). The free end of the L-bar (20) is pressed down on the arc-shaped elastic strip (21). At least one end of the elastic strip (21) is fixed on the fixed base plate (2).

5. A testing device for battery wiring harnesses according to claim 1, characterized in that, The front end of the contact rod (7) is an inclined surface.

6. The testing device for battery wiring harnesses according to claim 1, characterized in that, The front end of the contact rod (7) is an arc surface.

7. A testing device for battery wiring harnesses according to claim 1, characterized in that, A roller is installed at the front end of the contact rod (7).

8. A testing device for battery wiring harnesses according to claim 3, characterized in that, The upper clamping block (14) and the lower clamping block (15) each have multiple wire grooves (16), and each groove is set in a corresponding manner.

9. A testing device for battery wiring harnesses according to claim 3, characterized in that, The second spring (17) is a tension spring.

10. A testing device for battery wiring harnesses according to claim 1, characterized in that, The stroke of the electric push rod (4) is greater than the initial distance between the front end of the contact rod (7) and the inclined surface of the guide block (8).

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