Battery Connector Lockout Using Padlock Shackle Retention
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Solution Overview
Problem
Existing lockout devices for electrical connectors in 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 that uses a padlock shackle to securely retain connectors, featuring a reduced number of moving parts and a design that accommodates various connector types, including those with protective covers, to prevent accidental reconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lockout devices are used to prevent connector reconnection, then safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The lockout device is segmented into distinct functional elements: a base for stability, a protrusion for connector engagement, and an aperture for padlock integration. This segmentation allows each component to perform its specific function efficiently while keeping the overall design simple and manufacturable.
Solution Approach 2:
The lockout device base is designed to be universally compatible with various connector types through the standardized protrusion and aperture configuration. The same base structure can secure different connector shapes and sizes, reducing the need for multiple specialized lockout devices and simplifying manufacturing.
2Reliability
If traditional lockout devices are used to prevent connector reconnection, then safety is improved, but manufacturing cost increases
Solution Approach 1:
By dividing the lockout device into simple, discrete components (base, protrusion, aperture), each can be manufactured using standard, cost-effective processes. The segmented design allows for efficient molding and assembly, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The lockout device base is designed as a simple, potentially disposable component that can be manufactured at low cost. Rather than designing for long-term durability with complex mechanisms, the focus is on creating an inexpensive device that fulfills its safety function and can be replaced if needed.
3Reliability
If traditional lockout devices are used to retain connectors, then connector retention is improved, but ease of operation deteriorates
Solution Approach 1:
The locking mechanism is extracted from the lockout device base itself and replaced with a simple aperture that accommodates an external padlock. This extraction eliminates complex internal locking mechanisms from the base, making it simpler to manufacture and operate, while still providing secure connector retention through the padlock-shackle-aperture combination.
Data Source
Figure 1A~1C
Figure 1D~2B
Figure 2C~3A
AI summary
A lockout device (100) is provided, suitable for use with a connector for an automotive battery. The lockout device includes a base (110) including a protrusion (120) configured to receive a connector (140) and laterally retain the connector relative to the base, and a first aperture (130) configured to receive a shackle (152) of a padlock (150) 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.