Battery Connector Lockout with Padlock Shackle Retention
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Solution Overview
Problem
Existing connector lockout devices for vehicles are difficult to operate, prone to failure, and expensive to manufacture, posing a risk of accidental reconnection during maintenance, which can cause injuries and damage.
Innovation Solution
A simplified lockout device with a base and protrusion configured to receive a connector, featuring a shackle-compatible aperture to secure the connector using a padlock, reducing the number of moving parts and manufacturing costs, and designed to be compatible with various connector types, including those with integrated current sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector lockout devices are used to prevent accidental reconnection, then safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The lockout device is divided into separate functional components: a base for securing the connector, a protrusion for lateral retention, and an aperture for padlock integration. This segmentation allows each component to be simple in structure while collectively providing robust safety functionality.
Solution Approach 2:
The device leverages the user's existing padlock as the locking mechanism, rather than incorporating a complex built-in lock system. The aperture is designed to accommodate standard padlocks, allowing the user's own security device to serve the locking function, thereby simplifying the lockout device structure.
2Reliability
If traditional connector lockout devices are used to prevent accidental reconnection, then safety is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the device into a base, protrusion, and aperture, each part can be manufactured using simple, cost-effective processes. The base can be molded as a single piece with the protrusion and aperture integrated, reducing assembly costs and manufacturing complexity.
Solution Approach 2:
The lockout device is designed as an inexpensive, single-use component that can be discarded after one locking cycle. This allows the use of simple materials and manufacturing methods that would be too costly for reusable, high-durability applications, thereby reducing overall manufacturing cost while maintaining adequate safety for the intended use case.
3Reliability
If traditional connector lockout devices are used to prevent accidental reconnection, then safety is improved, but ease of operation decreases
Solution Approach 1:
The device uses the user's existing padlock skills and familiar locking mechanism, requiring no special training or complex操作流程. The user simply places the connector in the base, inserts their padlock through the aperture, and locks it - a straightforward process that leverages existing user capabilities rather than requiring learning new complex operations.
Solution Approach 2:
Instead of designing a complex built-in locking mechanism that the user operates, the design inverts the approach by having the user's padlock perform the locking function. This reversal simplifies the operation to basic padlock usage while maintaining robust safety through the secure mechanical retention of the connector.
Data Source
AI summary
A lockout device is provided, suitable for use with a connector for an automotive battery. The lockout device includes a base including a protrusion configured to receive a connector and laterally retain the connector relative to the base, and a first aperture configured to receive a shackle of a padlock to position at least a portion of the connector between the shackle and the protrusion such that the shackle retains the connector at the protrusion. A lockout arrangement and connector arrangement are also provided.