Battery Sensor Clamp Assembly with Tapered Wedge Mechanism
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Solution Overview
Problem
Conventional battery sensor clamps for automotive vehicles lack an efficient mechanism to securely attach sensors to battery posts, particularly in designs that require easy assembly and compatibility with various vehicle configurations.
Innovation Solution
A clamp assembly featuring a surround portion with clamping arms and a U-shaped wedge, where the wedge's base is narrower than its distal ends, allows for a clamping force to be applied by a fastener and nut, ensuring secure attachment of battery sensors to vehicle battery posts with minimal waste and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional clamp design with horizontally oriented fastener is used, then the clamp can provide clamping force around the battery post, but the assembly complexity increases and compatibility with various vehicle configurations is reduced
Solution Approach 1:
The clamp assembly employs asymmetric design where the wedge member has a tapered configuration with a narrow end and a wide end, allowing the clamp arms to be positioned at different heights relative to the battery post. This asymmetric structure enables the same clamp design to accommodate various battery post positions and configurations without requiring multiple specialized clamp designs, thereby improving adaptability while maintaining manageable assembly complexity
Solution Approach 2:
The clamp assembly is divided into distinct functional segments: clamp arms for surrounding the battery post, a wedge member for adjusting the clamping force, and a fastener for securing the components. This segmentation allows each component to perform its specific function independently, simplifying the overall assembly process and enabling easier adaptation to different vehicle configurations by adjusting individual segments rather than redesigning the entire clamp
2Force
If the wedge base width is made narrower than distal ends, then the clamp arms are forced toward one another to apply clamping force, but the manufacturing precision requirements increase
Solution Approach 1:
The wedge member utilizes a tapered geometric parameter transition, where the base width is intentionally made narrower than the distal end width. This parameter change creates a mechanical advantage that converts the rotational motion of the fastener into linear clamping force on the clamp arms. The tapered geometry naturally amplifies the clamping force while the gradual transition reduces sensitivity to manufacturing tolerances, allowing standard manufacturing processes to produce the required precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a secure, efficient, and versatile method for attaching battery sensors, ensuring reliable data collection while being compatible with different vehicle configurations and reducing manufacturing complexity.
Implementation Method 1
the width at the base of the wedge forces the clamp arms toward one another
Data Source
AI summary
A clamp assembly (10) for securing a battery sensor to a vehicle battery comprises a surround portion (16) defining an aperture (24) for at least partially surrounding a battery post for the vehicle battery and a pair of clamping arms (26) extending from opposing ends of the surround portion (16). A tab (34) extends from one of the clamp arms (26) toward the other of the clamp arms (26), wherein the tab (34) defines a first through hole (36). A wedge (28) has a generally U-shaped cross-section, where a width of the base (30) of the wedge (28) is less than a width at distal ends (32) of the U-shaped cross-section and the base (30) of the wedge (28) defines a second through hole (38). The wedge (28) is fitted over the clamping arms (26) and a fastener (22) is threaded through the first and the second through holes (36,38). A nut (40) is threaded on the fastener (22) to force the wedge (28) over the clamp arms (26) such that the width at the base (30) of the wedge (28) forces the clamp arms (26) toward one another.