Battery collection wire harness external switching device

Abstract

An external adapter for battery data acquisition harnesses belongs to the field of battery box maintenance technology. This external adapter includes: a harness connection part for connecting to a female connector of the battery box to transmit current; an adapter part with an adapter platform electrically connected to the harness connection part, used at least to transfer current between the harness connection part and the harness connection part; an external socket electrically connected to the adapter platform; and a terminal block part electrically connected to the external socket, the terminal block part including at least one terminal, the terminal block having an output terminal and an input terminal corresponding to the holes of the female connector. This external adapter makes voltage and resistance detection and battery balancing operations more convenient and efficient.

Description

Technical Field

[0001] This utility model belongs to the field of battery box maintenance technology, specifically relating to an external adapter for battery acquisition harness that simplifies battery box maintenance operations. Background Technology

[0002] In energy storage battery systems, voltage and temperature data within the battery compartment are typically transmitted to the Battery Management Unit (BMU) via a data acquisition harness to enable real-time monitoring and management of the battery status. However, existing detection and maintenance methods present numerous inconveniences when abnormal battery voltage or temperature data occurs.

[0003] Currently, the data acquisition harnesses inside battery boxes typically use female connectors at the ends, with extremely small hole sizes (e.g., 0.62 × 0.52 mm). This makes it difficult for external testing equipment (such as multimeters) to directly measure voltage or resistance values, and also poses a short-circuit risk. Therefore, when it is necessary to confirm anomalies or perform battery equalization, specialized equipment (such as a forklift) is usually required to remove the battery box from the rack and open the battery box cover before testing and maintenance can be performed. This method is not only cumbersome to operate, but also increases manufacturing costs and the difficulty of after-sales maintenance.

[0004] The aforementioned defects are manifested in the following aspects:

[0005] The extremely small terminal holes and spacing of the data acquisition harness connectors make it difficult to directly measure voltage or temperature resistance with a multimeter, affecting troubleshooting efficiency. Because the data acquisition harness connectors are female terminals, external power supply equipment (such as power supply devices) cannot be directly wired, increasing the difficulty of battery equalization. Both in the factory and at the project site, it is necessary to disassemble the battery box cover for inspection and maintenance, which not only increases labor and time costs but may also affect the overall operating efficiency of the battery system. Utility Model Content

[0006] To address the aforementioned technical problems, this application further improves the adapter structure for battery box maintenance, aiming to resolve these issues. The purpose of this utility model is to provide an external adapter device for battery acquisition harnesses.

[0007] The specific technical solution is explained below:

[0008] An external adapter for a battery acquisition harness includes:

[0009] The wiring harness connector is used to connect to the female connector of the battery box to transmit current.

[0010] The adapter is provided with an adapter platform, which is electrically connected to the wire harness connection part and is used at least to transfer the current between the adapter and the wire harness connection part;

[0011] An external socket is electrically connected to the adapter platform;

[0012] The wiring terminal section is electrically connected to the external socket. The wiring terminal section includes at least one wiring terminal, and the wiring terminal is provided with an output terminal and an input terminal corresponding to the hole positions of the female connector.

[0013] In a preferred embodiment, the wire harness connector and the external socket are respectively located on opposite sides of the adapter platform.

[0014] In a further embodiment, the wiring terminal portion is disposed on the side of the external socket away from the wire harness connection portion.

[0015] In a further embodiment, the output terminal and the input terminal have different orientations.

[0016] In a preferred embodiment, there are two terminals, which are arranged side by side on the external socket.

[0017] In some implementations, the terminal block is detachably connected to the external socket by bolts.

[0018] In some embodiments, the wire harness connector is a male connector.

[0019] In a preferred embodiment, the adapter is a PCB adapter board.

[0020] In a further embodiment, the exposed solder joints and pins on the PCB adapter board are covered with an insulating layer.

[0021] In a preferred embodiment, the output terminals have the same number as the holes, and the input terminals have the same number as the holes.

[0022] In summary, the technical solution described in this utility model has the following main beneficial effects:

[0023] Compared with the prior art, the external adapter device described in this utility model makes voltage and resistance detection and battery balancing operations more convenient and faster.

[0024] Furthermore, this external adapter has a reasonable component layout, a more compact structure, and is easier to operate.

[0025] Further or more detailed beneficial effects will be described in conjunction with specific embodiments in the detailed implementation. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the wiring harness panel structure of a battery box in the prior art;

[0027] Figure 2 yes Figure 1 Enlarged view of area A;

[0028] Figure 3 This is a schematic diagram of the battery box in the open state in the existing technology;

[0029] Figure 4 This is a three-dimensional structural diagram of the external adapter device in the embodiments of this application;

[0030] Figure 5 This is a top view of the external adapter in the embodiments of this application;

[0031] Figure 6 This is a schematic diagram of the usage state of the external adapter device used for battery balancing in the embodiments of this application.

[0032] Figure label:

[0033] a: Battery box, a.1: Female connector, a.11: Hole position;

[0034] 1: Wire harness connection part;

[0035] 2: Adapter section; 2.1: Adapter platform;

[0036] 3: External socket;

[0037] 4: Terminal block section, 4.1: Terminal block, 4.11: Output terminal, 4.12: Input terminal. Detailed Implementation

[0038] The present invention will be further explained in conjunction with the embodiments:

[0039] The core technical problem faced by the technical solution of the embodiments of this application stems from the inventor's accurate understanding of the prior art. Therefore, how to solve the defects of cumbersome battery box maintenance and high cost is a technical problem that the inventor urgently needs to solve.

[0040] It should be noted that the embodiments do not constitute a limitation on the scope of protection of the claims of this utility model. All technical solutions that can be reasonably expected by those skilled in the art based on the technical concepts provided / proved by the embodiments should be covered within the scope of protection of the claims of this utility model.

[0041] The specific implementation examples are detailed below:

[0042] Please refer to the attached document. Figures 1-3 In existing technologies, such as Figure 1As shown, the voltage and temperature data inside battery box a are acquired by outputting electrical signals through the female connector a.1. During normal operation, the harness connector needs to be inserted into the battery management acquisition unit (BMU) to collect voltage and temperature data.

[0043] When the battery voltage or temperature is abnormal, it is necessary to use external equipment to measure the data at the abnormal point - hole a.11, such as... Figure 2 As shown, the size of the hole a.11 is very small, 0.62*0.52mm. It is difficult for external devices (such as multimeters) to directly measure the actual voltage or temperature of the abnormal point through the female port corresponding to the hole a.11, and there is a risk of short circuit.

[0044] The main reason why the female connector a.1 is difficult to wire to external power supply equipment is that the female terminal needs to be in close contact with the male terminal through the elastic cantilever to ensure conductivity. If the female terminal is not elastic enough, has surface oxidation or impurities, it will increase the contact resistance, resulting in wiring difficulties or poor contact. Some female terminals need to be assembled with a secondary locking structure or special tools. Improper operation can easily lead to terminal deformation or failure to lock, affecting the wiring.

[0045] like Figure 3 As shown, the battery compartment cover needs to be opened at this point to identify the problem and perform necessary maintenance.

[0046] Please refer to the attached document for further details. Figures 4-6 This embodiment relates to an external adapter for a battery acquisition harness, which includes a harness connection part 1, an adapter part 2, an external socket 3, and a wiring terminal part 4.

[0047] The wiring harness connection part 1 is used to connect to the female connector a.1 of the battery box a to transmit current; the adapter part 2 is provided with an adapter platform 2.1, which is electrically connected to the wiring harness connection part 1 and is used to transfer the current between the wiring harness connection parts 1; the external socket 3 is electrically connected to the adapter platform 2.1; the terminal part 4 is electrically connected to the external socket 3, and the terminal part 4 includes at least one terminal 4.1, which is provided with an output terminal 4.11 and an input terminal 4.12 corresponding to the hole position a.11 of the female connector a.1. The technical solution of this embodiment converts the hole position a.11 of the female connector a.1, which is originally difficult to measure directly, into an easily operable output terminal 4.11 and input terminal 4.12 through an external adapter, solving the measurement difficulties and short circuit risks caused by the small hole size in the prior art. When the voltage or temperature sampling in the battery box is abnormal, the voltage or resistance value of the output terminal 4.11 can be directly measured with a multimeter to quickly locate the source of the abnormality; such as Figure 6As shown, when the battery needs to be balanced, the balancing operation can be performed by connecting the charging device to the input terminal 4.12 without removing the cover for maintenance, which significantly reduces the difficulty of operation and maintenance costs.

[0048] In a preferred embodiment, the wiring harness connector 1 and the external socket 3 are respectively located on opposite sides of the adapter platform 2.1. This layout design places the connection interface and expansion interface on opposite sides of the adapter platform, forming a clear signal flow path and avoiding cable tangling and spatial conflicts. By symmetrically distributing the functional modules, not only is the device structure more compact, but the utilization rate of internal wiring space is also optimized, facilitating installation and use in confined environments. This design is particularly suitable for scenarios where space around the battery box is limited, enabling efficient adapter functionality without increasing the overall size.

[0049] In a further embodiment, the terminal block 4 is located on the external socket 3 on the side away from the wiring harness connection part 1. This external layout fully exposes the terminal block 4 to the operator's field of vision, providing ample operating space for inspection and maintenance. Technicians can directly access the output terminal 4.11 without having to avoid other components when performing voltage or resistance measurements; the input terminal 4.12 can also be easily connected when using a voltage converter. This design significantly improves the convenience of inspection and maintenance operations, and is particularly suitable for scenarios requiring frequent measurement operations.

[0050] In a preferred embodiment, the output terminal 4.11 and the input terminal 4.12 have different orientations. By differentiating the terminal orientations, mutual interference between test probes or power supply connectors during operation can be avoided, and the three-dimensional space of the wiring terminal 4.1 is fully utilized. For example, the output terminal 4.11 can be oriented upwards for easy vertical insertion of the multimeter probes, while the input terminal 4.12 can be arranged horizontally to accommodate the insertion and removal direction of the power supply connector. This space-optimized design achieves a reasonable arrangement of multifunctional terminals within a limited area, ensuring operational convenience while avoiding the risk of accidental contact.

[0051] In a preferred embodiment, there are two terminals 4.1, arranged side-by-side on the external socket 3. This side-by-side layout satisfies both voltage detection and battery equalization requirements while controlling the overall size of the device through a compact arrangement. Specifically, the terminals 4.1 employ a pluggable structure, and their spacing is designed to accommodate the probe spacing of standard testing equipment, ensuring that no short circuits occur during measurement. This arrangement, combined with the plate-shaped adapter 2, forms a modular structure, achieving device miniaturization while maintaining functional integrity.

[0052] In a preferred embodiment, the terminal block 4.1 is detachably connected to the external socket 3 by bolts. The bolted connection ensures connection strength while facilitating assembly and disassembly using common tools. This fixing method maintains stable contact in vibrating environments, and individual terminals can be replaced individually without scrapping the entire device when worn or damaged. The detachable design also facilitates the replacement of different specifications of terminal blocks 4.1 according to different testing requirements, extending the service life of the adapter and reducing maintenance costs.

[0053] In a preferred embodiment, the wire harness connection part 1 is a male connector. This male connector adopts a specification that matches the female connector a.1 of the battery box, with its pin arrangement and mechanical dimensions perfectly corresponding to the distribution of holes a.11. The connector is equipped with a locking mechanism (such as a spring clip or a rotating locking tab) to ensure reliable mechanical fixation and electrical contact after insertion. This design maintains compatibility with the original connector while achieving quick connection through a pluggable structure, simplifying the operation process while ensuring signal transmission quality.

[0054] In a preferred embodiment, the adapter 2 is a PCB adapter board. This PCB board uses FR-4 substrate, is 1.6mm thick, has a copper foil weight of 2oz, and employs a double-layer design to balance mechanical strength and wiring density. Its circuit layout utilizes high-density interconnect technology to achieve complete signal transmission, and the shortest path principle is used for critical signal paths to reduce delay. The PCB board is designed with a continuous overcurrent capability of 3A to meet the current requirements for battery detection and balancing. This design not only improves integration and supports parallel transmission of multiple signal channels, but also effectively suppresses electromagnetic interference, ensuring the accuracy of measurement data.

[0055] Exposed solder joints and pins on the PCB adapter board are covered with an insulating layer. This insulating layer, made of high-temperature resistant silicone material with a thickness controlled between 0.2-0.3 mm, effectively isolates adjacent solder joints without affecting component heat dissipation. This insulating layer completely covers all live parts, including the mounting base area of ​​terminal block 4.1, completely eliminating the risk of accidental short circuits during operation. This protection is crucial for ensuring voltage measurement accuracy and battery balancing efficiency, especially important in high humidity or dusty environments.

[0056] In a preferred embodiment, the number of output terminals 4.11 and input terminals 4.12 is the same as the number of holes a.11 on the female connector a.1. Each hole a.11 corresponds to an independent output terminal 4.11 and input terminal 4.12, forming a complete signal mapping relationship. This one-to-one design ensures that voltage and temperature data at all sampling points within the battery box can be monitored, while supporting precise equalization of any individual battery cell. The comprehensive interface design avoids detection blind spots, provides complete data support for battery system maintenance, and significantly improves the comprehensiveness of fault diagnosis and the targeted nature of maintenance operations.

[0057] In the description of this specification, the references to terms such as "embodiment," "basic embodiment," "preferred embodiment," "other embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0058] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0059] Obviously, those skilled in the art can make various modifications and variations to this utility model without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this utility model and their equivalents, this utility model also intends to include these modifications and variations.

Claims

1. A battery acquisition harness external adapter, characterized in that, Including: The wire harness connection part (1) is used to connect to the female connector (a.1) of the battery box (a) to transmit current; The adapter (2) is provided with an adapter platform (2.1), which is electrically connected to the wire harness connection part (1) and is used at least to transfer the current between the adapter and the wire harness connection part (1); An external socket (3) is electrically connected to the adapter platform (2.1); The wiring terminal section (4) is electrically connected to the external socket (3). The wiring terminal section (4) includes at least one wiring terminal (4.1). The wiring terminal (4.1) is provided with an output terminal (4.11) and an input terminal (4.12) corresponding to the hole (a.11) of the female connector (a.1).

2. The external adapter according to claim 1, characterized in that: The wire harness connector (1) and the external socket (3) are respectively located on opposite sides of the adapter platform (2.1).

3. The external adapter according to claim 2, characterized in that: The terminal block (4) is located on the side of the external socket (3) away from the wire harness connection part (1).

4. The external adapter according to claim 3, characterized in that: The output terminal (4.11) and the input terminal (4.12) have different orientations.

5. The external adapter according to claim 3, characterized in that: The number of the wiring terminals (4.1) is two, and the two wiring terminals (4.1) are arranged side by side on the external socket (3).

6. The external adapter according to claim 1 or 5, characterized in that: The terminal block (4.1) is detachably connected to the external socket (3) by bolts.

7. The external adapter according to claim 1, characterized in that: The wire harness connection part (1) is a male connector.

8. The external adapter according to claim 1, characterized in that: The adapter (2) is a PCB adapter board.

9. The external adapter according to claim 8, characterized in that: The exposed solder joints and pins on the PCB adapter board are covered with an insulating layer.

10. The external adapter according to claim 1, characterized in that: The output terminals (4.11) have the same number as the holes (a.11), and the input terminals (4.12) have the same number as the holes (a.11).

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