Battery Nut Mounting Sleeve for Short-Circuit-Safe Assembly
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Solution Overview
Problem
In battery assembly mounting processes, there is a risk of unintentional short circuits and electrical shocks due to the handling of small nuts and screws, which complicates the process and increases safety hazards and costs.
Innovation Solution
A mounting device with a receptacle and holding element that keeps the nut at a distance from the screw, allowing for easier handling and insulation, reducing the risk of electrical contact and simplifying the mounting process by using a larger device to position the nut over the screw.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar is surrounded with multi-part modules to shield electrically conductive parts, then occupational safety is improved, but device complexity increases
Solution Approach 1:
The mounting device is divided into functionally independent components: a mounting body for structural support, a holding element for securing the nut, and an electrically insulating coating for safety. This segmentation allows each component to perform its specific function efficiently while maintaining overall system safety without requiring complex multi-part modular connectors.
Solution Approach 2:
The electrically insulating coating acts as an intermediary layer between the electrically conductive busbar and the surrounding environment. This coating provides electrical insulation and occupational safety without requiring additional multi-part modules, thereby reducing device complexity while maintaining safety standards.
2Reliability
If an electrically insulating collar surrounds the busbar contact surface, then protection against short circuits is improved, but ease of operation deteriorates due to manual insertion requirements
Solution Approach 1:
The mounting device merges multiple functions into a single integrated component: the mounting body provides structural support, the holding element secures the nut, and the electrically insulating coating provides protection against short circuits. This integration eliminates the need for separate collars that require manual insertion, thereby improving ease of operation while maintaining protection against short circuits.
Solution Approach 2:
The mounting device is designed to be self-positioning and self-securing. The holding element automatically holds the nut in place during the mounting process, and the electrically insulating coating provides continuous protection without requiring manual intervention. This self-service design improves ease of operation by eliminating the need for manual insertion and adjustment of protective components.
3Reliability
If protective clothing and gloves are used during mounting, then occupational safety is improved, but mounting time increases
Solution Approach 1:
The electrically insulating coating on the mounting device serves as an intermediary protective layer that provides occupational safety without requiring additional protective clothing or gloves. This coating allows the mounting process to proceed quickly while maintaining safety standards, thereby reducing mounting time while preserving occupational safety.
4Ease of operation
If the nut is held by hand during mounting, then ease of operation is maintained, but occupational safety deteriorates due to risk of electrical shock
Solution Approach 1:
The mounting device acts as an intermediary tool that eliminates direct hand contact with electrically conductive parts. The electrically insulating coating on the mounting device provides occupational safety by preventing electrical shock, while the holding element maintains ease of operation by securely holding the nut during the mounting process.
Solution Approach 2:
The mounting device replaces the mechanical system of direct hand handling with a tool-based system. The holding element mechanically secures the nut, and the electrically insulating coating provides protection against electrical shock. This substitution maintains ease of operation while significantly improving occupational safety by eliminating the risk of electrical shock associated with direct hand contact.
Data Source
AI summary
The present invention relates to a mounting device for mounting a nut on a screw of a battery assembly, comprising a mounting body having a receptacle extending continuously in a longitudinal direction for receiving the nut, and a holding element extending radially inwardly in the receptacle for holding the nut in a pre-mounting position distanced from the screw as well as a battery assembly comprising the mounting device.