Modular Battery Probe Assembly for Deep Cabinet Terminal Testing
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Solution Overview
Problem
Existing battery probe sets are unable to easily assess battery terminals within the deepest regions of storage cabinets due to limited reach and visibility issues, particularly in low light conditions, making regular battery testing in UPS systems difficult and unsafe.
Innovation Solution
A modular battery probe set with adjustable length probe stems and integrated lighting, allowing for extended reach and improved visibility, enabling safe and efficient testing of batteries within cabinets without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional battery probes are used to test batteries in storage cabinets, then testing can be performed, but the probes cannot reach battery terminals in the deepest regions of the cabinet
Solution Approach 1:
The probe is divided into multiple segments including an extendable stem with telescoping sections, allowing the probe to be segmented into different length configurations. This enables the probe to reach deep into battery cabinets while maintaining maneuverability when retracted to shorter lengths.
Solution Approach 2:
The probe incorporates dynamic length adjustment capabilities through extendable and retractable stem sections. This allows the probe to dynamically change its length based on the specific testing location, reaching deep terminals when needed and reducing length for easier handling in confined spaces.
2Illumination intensity
If conventional battery probes are used in low light conditions, then testing can be performed, but visibility of battery terminals is insufficient
Solution Approach 1:
The probe combines multiple functions into a single device: electrical measurement capabilities are merged with integrated LED lighting and wireless communication. This integration allows the probe to simultaneously illuminate the battery terminal for visibility while performing measurements and transmitting data, eliminating the need for separate lighting equipment.
Solution Approach 2:
The probe provides self-illumination through its integrated LED light source, which automatically activates to illuminate the battery terminal during testing. This self-service lighting capability allows the probe to create its own working illumination without requiring external light sources or additional energy infrastructure.
3Measurement precision
If batteries are removed from cabinets for testing, then accurate measurements can be obtained, but the process is time-consuming and disruptive
Solution Approach 1:
The probe serves as an intermediary tool that enables accurate measurements to be taken in-situ within the battery cabinet. By incorporating extended reach capabilities and adaptive positioning features, the probe mediates between the need for precise terminal contact and the constraint of maintaining batteries in their installed positions, eliminating the need for battery removal.
Solution Approach 2:
The probe is designed with universal applicability to test batteries in various configurations and locations within cabinets. The combination of extendable reach, adjustable angle, and multiple measurement capabilities allows a single probe to perform accurate tests on batteries whether they are easily accessible or deep within cabinet structures, maintaining productivity across different testing scenarios.
4Reliability
If protective gear is worn for battery testing, then safety is improved, but the testing process becomes more complex and time-consuming
Solution Approach 1:
The probe incorporates safety features that convert potential harmful situations into beneficial outcomes. For example, the probe includes isolated measurement circuits that prevent electrical shock hazards, and the extended reach capability allows testing without direct hand contact with potentially dangerous battery terminals, thereby reducing the need for extensive protective gear while maintaining or improving safety.
Solution Approach 2:
The probe replaces manual mechanical interaction with batteries through automated measurement and wireless data transmission. This substitution eliminates the need for complex mechanical protective barriers by using electronic isolation and remote sensing capabilities, simplifying the overall testing procedure while maintaining high safety standards.
Data Source
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AI summary
The present disclosure relates to a battery probe set configured to plug into a battery tester and impinge upon one or more terminals of a battery. The battery probe set includes first and second probe assemblies, each including a housing with gripping portions and conductive ports, probe stems of varying lengths that attach to the housing, and probe tips that couple to the probe stems. The housing, probe stem, and probe tips are electrically coupled via conductive paths. The first and second probe assemblies are electrically coupled via a transverse connector, permitting the location of probe plugs onto one of the probe assemblies that is configured to be pluggable into the battery tester. The probe tips are interchangeable and include a light source.