Battery Temperature Sensor with Detachable Connector Housing
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Solution Overview
Problem
In existing battery temperature sensor systems, replacing a battery temperature sensor requires disassembling and reassembling the busbar module attached to the battery stack, making it necessary to replace the entire stack, which is inefficient and inconvenient.
Innovation Solution
A battery temperature sensor with a detachable connector housing and sensor housing allows for easy replacement of the sensor body without disconnecting the electric wire from the busbar module, using a locking mechanism that separates the sensor body from the electric wire connecting connector, enabling individual replacement of the sensor without affecting the busbar module's fixation to the battery stack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery temperature sensor is integrated with the busbar module using a fixed connection structure, then the structural integrity and reliability are improved, but the ease of repair deteriorates because replacing the sensor requires disassembling the busbar module from the battery stack
Solution Approach 1:
The battery temperature sensor is divided into separate modular components: a sensor body with temperature measuring element, a connector housing with locking mechanism, and electric wire connection terminals. This segmentation allows the sensor to be replaced as a complete unit without disassembling the busbar module from the battery stack, resolving the contradiction between structural integrity and ease of repair.
Solution Approach 2:
The connection structure transitions from a fixed permanent bond to a dynamic removable connection using a locking mechanism. The locking member can engage to secure the connector housing to the sensor body during operation, providing reliability, but can be released to allow easy sensor replacement when needed, addressing both structural integrity and ease of repair requirements.
2Reliability
If the sensor body is permanently fixed to the electric wire using soldering and crimping, then the electrical connection reliability is improved, but the ease of repair deteriorates because the sensor cannot be easily detached for replacement
Solution Approach 1:
The electrical connection structure is segmented into detachable components: terminals in the connector housing that connect to electric wires, and a sensor body with leads. The locking mechanism enables these segments to be securely connected during operation for reliable electrical contact, yet easily separated when sensor replacement is needed.
Solution Approach 2:
The connector housing acts as an intermediary component between the sensor body and electric wires. It provides a standardized interface with locking and electrical connection functions, allowing the sensor body to be reliably connected to the wire bundle while enabling easy detachment by releasing the locking mechanism, thus resolving the contradiction between connection reliability and replacement ease.
3Stability of the object's composition
If the busbar module is fixed to the battery stack as an integral assembly, then the structural stability is improved, but the productivity deteriorates because sensor replacement requires replacing the entire battery stack
Solution Approach 1:
The battery temperature sensor system is segmented into a replaceable sensor unit and a fixed busbar module assembly. The sensor body with connector housing can be independently removed from the electric wire bundle without disturbing the busbar module's attachment to the battery stack, enabling quick sensor replacement and improving maintenance productivity while preserving structural stability.
Solution Approach 2:
The connection between the sensor and busbar system is made dynamic through the locking mechanism. During normal operation, the locked connection provides structural stability. When maintenance is needed, the locking mechanism can be released to allow rapid sensor replacement, eliminating the need to replace the entire battery stack and thus improving productivity.
Data Source
AI summary
A battery temperature sensor includes a sensor body and an electric wire connecting connector. The sensor body includes a sensor housing configured to be detachably attached to a mating body, a first locking member provided on the sensor housing and configured to be locked to the mating body, and a temperature measuring element integrally formed in the sensor housing. The electric wire connecting connector includes a connector housing configured to be detachably attached to the sensor housing, a second locking member provided on the connector housing and configured to be locked to the sensor housing, and a pair of terminals attached to the connector housing. The terminals are electrically connected to the pair of leads respectively when the connector housing is coupled to the sensor housing.