Vehicle Battery Sensor Form-Fitting Housing Design
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Solution Overview
Problem
Battery sensors for vehicle batteries require a compact and mechanically stable design to withstand the forces acting on them during vehicle operation, particularly tensile forces, while maintaining the integrity of current measurement without compromising electrical resistance.
Innovation Solution
A battery sensor design featuring two line sections with a measuring resistor and a housing that encloses the measuring resistor and line sections, utilizing form-fitting holding sections to absorb tensile forces and reduce mechanical loads on other components, achieved through injection molding or embossing of the housing onto the line sections and measuring resistor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery sensor is made compact for installation in battery terminals, then the installation space requirement is reduced, but the mechanical stability under tensile forces deteriorates
Solution Approach 1:
The battery sensor is divided into functionally independent segments: the measuring resistor section for electrical measurement and the housing with retaining sections for mechanical support. This segmentation allows the housing to be specifically designed for mechanical stability while keeping the overall sensor compact, resolving the contradiction between small size and mechanical strength.
Solution Approach 2:
The housing is made of plastic material that is injection-molded onto the conductor sections and measuring resistor, creating a composite structure. This composite design provides both the compact enclosure needed for small installation space and the mechanical strength to withstand tensile forces during vehicle operation.
2Strength
If retaining sections are added to absorb tensile forces, then the mechanical stability is improved, but the device complexity increases
Solution Approach 1:
The retaining sections are integrated directly into the housing structure through injection molding, merging the mechanical support function with the housing's protective function. This eliminates the need for separate mechanical fastening components, thereby improving tensile force absorption without significantly increasing device complexity.
Solution Approach 2:
The housing itself serves dual purposes: it protects the internal components and simultaneously provides mechanical anchoring through the retaining sections that engage with the conductor sections. This self-service approach allows the housing to absorb tensile forces without requiring additional specialized components.
3Volume of moving object
If the cross-sectional area is reduced to maintain compactness, then the volume is reduced, but the electrical resistance increases
Solution Approach 1:
The retaining sections are positioned in edge regions or on the housing exterior rather than reducing the cross-sectional area of the current-carrying conductor sections. This local differentiation ensures that the compact housing design does not compromise the electrical conductivity of the measuring resistor and conductor sections, maintaining manufacturing precision for electrical resistance.
Data Source
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AI summary
The invention relates to a battery sensor (10), particularly for a vehicle battery, comprising two conductor sections (12, 16), a measuring resistor (20) arranged between the conductor sections (12, 16), a voltage detection device for detecting a voltage drop across the measuring resistor (20), and a housing (22) that at least partially encloses the measuring resistor (20), the voltage detection device, and the conductor sections (12, 16). At least one retaining section (32, 34) is provided on at least one of the conductor sections (12, 16) and/or on the measuring resistor (20), into which the housing (22) engages in a form-fitting manner, establishing a positive connection between the at least one retaining section (32, 34) and the housing (22). The invention further relates to a method for manufacturing such a battery sensor (10).