Battery Cable Quick-Connection Anti-Locking Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing quick connection systems for electrical cables to battery terminals often suffer from poor fitting due to manufacturing tolerances and operational challenges, leading to incomplete connections, loss of conduction, and premature oxidation, which can result in vehicle stoppages and electrical issues.
Innovation Solution
An anti-locking system that verifies correct fitting by ensuring the terminal is fully inserted before allowing locking, using a movable detector and return spring mechanism to prevent locking if the connection is not properly made, ensuring the lever remains raised if the connection is incorrect, thus preventing incomplete fittings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a quick connection system is used to enable rapid connection without tools, then productivity is improved and assembly time is reduced, but fitting precision deteriorates leading to poor connections and incomplete fittings
Solution Approach 1:
The detector is positioned and configured in advance to verify correct fitting before locking occurs. The anti-locking mechanism is pre-set to prevent locking unless the terminal is fully inserted, ensuring precision is checked before final connection is made.
Solution Approach 2:
The detector provides immediate feedback on whether the terminal is correctly fitted before locking is authorized. The system gives real-time information to the operator about connection status, allowing correction before final locking occurs.
2Ease of manufacture
If manufacturing tolerances are allowed during terminal production to reduce costs, then ease of manufacture is improved, but connection reliability deteriorates due to incorrect positioning
Solution Approach 1:
The detector is designed to detect specific geometric parameters of the battery top surface and terminal positioning. By monitoring these parameters, the system compensates for manufacturing tolerances and ensures correct positioning even when dimensions vary within acceptable ranges.
Solution Approach 2:
The detector acts as an intermediary between the terminal and locking mechanism. It verifies positioning accuracy and only allows locking when correct positioning is confirmed, mediating between manufacturing variations and connection reliability requirements.
3Device complexity
If the locking mechanism is simplified to reduce device complexity, then ease of operation is improved, but the ability to prevent incomplete fitting deteriorates
Solution Approach 1:
The detector and anti-locking mechanism are merged into a single integrated system. The detector's position directly controls the locking capability, combining verification and locking functions into one unified mechanism rather than separate systems.
Solution Approach 2:
The system automatically verifies fitting correctness and controls locking without requiring external verification or complex control systems. The detector self-activates based on terminal insertion and automatically enables or disables locking based on verification results.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Guarantees reliable and long-term functionality by ensuring correct positioning and complete insertion of the terminal, eliminating issues of poor fixing and oxidation, while being economically advantageous with low manufacturing costs and easy maintenance.
Implementation Method 1
a return spring (8) which has the effect of restoring the detector (6) into its initial position
Implementation Method 2
The fixing of the lug (1) on the battery terminal is carried out by means of a clamping spring (2)
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a battery connection system with an anti-locking system comprising an electrical cable connecting unit (3) equipped with a lever (5) articulated between a locked position and an unlocked position. The connection has an anti-locking system preventing the said lever (5) from being lowered and therefore preventing the connection from being locked onto the terminal (9) of the battery if the connections have not been made correctly. The anti-locking system comprises a detector (6) able to move between two configurations which correspond to the locked position and to the unlocked position of the connection and is able, in the configuration corresponding to the locked position, to rest against a surface of the battery on which the terminal (9) is located.