Battery Sensor Clamp With Integrated Support Element
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Solution Overview
Problem
Existing battery sensors face challenges in maintaining stability and reliability under mechanical loads such as vibrations and tensile forces during vehicle operation, leading to increased complexity and cost in production due to the need for additional holding elements.
Innovation Solution
A battery sensor design featuring a separate support element integrated into the housing, which absorbs mechanical loads away from the detection device, allowing for independent mechanical and electrical design, and produced using injection molding for a secure form-fit connection without additional manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional mechanical holding elements are used to absorb forces acting on the cable, then the stability and reliability of the battery sensor under mechanical loads is improved, but the production complexity and cost increase
Solution Approach 1:
The patent combines the mechanical holding function and the electrical contacting function into a single integrated battery pole clamp structure. The holding section is formed as an integral part of the ring section, eliminating the need for separate mechanical holding elements. This merging reduces production complexity while maintaining the ability to absorb mechanical forces through the clamping mechanism.
2Reliability
If additional mechanical holding elements are used to absorb forces, then the protection of detection devices against mechanical loads is improved, but the installation space requirements and assembly complexity increase
Solution Approach 1:
The patent segments the battery pole clamp into functionally distinct sections: a ring section for receiving the battery pole and a holding section for making electrical contact with the cable connection. The holding section is positioned to absorb mechanical forces away from the detection device, providing protection without requiring additional space or complex assembly steps.
3Reliability
If the holding function is separated from the electrical contacting function, then the load absorption capability is improved and detection devices are better protected, but the device structure becomes more complex
Solution Approach 1:
The patent merges the holding function and electrical contacting function into a single integrated holding section that is formed as one piece with the ring section. This integration allows the holding section to absorb mechanical loads while maintaining electrical contact, without requiring separate components. The detection device remains protected as the holding section absorbs forces before they can reach the sensitive components.
Data Source
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AI summary
The invention relates to a battery sensor (12) for detecting at least one battery parameter, comprising a battery terminal clamp (14) for contacting a battery terminal of a vehicle battery, a cable connection (18) electrically connected to the battery terminal clamp (14), a detection device (34) for the at least one battery parameter, which is arranged, in particular electrically, between the battery terminal clamp (14) and the cable connection (18), wherein the battery terminal clamp (14) has an annular section (15) for receiving the battery terminal and a retaining section (16) provided on the annular section (15) for electrical contact with the cable connection (18) and/or the detection device (34), and a housing (32) that at least partially encloses the detection device (34). At least one support element (42), separate from the retaining section (16), is provided on the annular section (15) and is positively engaged in the housing (32).