Vertical Battery Terminal Current Sensor With Protected Clamping
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Solution Overview
Problem
Existing current sensors for vehicle batteries face issues with mechanical instability and safety due to the clamping flange rising during tightening, leading to incomplete engagement and potential electrical connections, and lack adequate mechanical protection and safety features.
Innovation Solution
An electronic device with a protective enclosure and movable upper cover surrounding the clamping actuation means, allowing secure clamping around a battery terminal using a tool along a parallel axis, and featuring a U-shaped flange and screw-nut mechanism to prevent vertical and lateral connections, with a signal output offset for easy cable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clamping flange with horizontal screw and nut is used to tighten around the battery terminal, then the device can be securely fastened to the terminal, but the flange rises up the terminal during tightening and may not be fully engaged
Solution Approach 1:
The patent inverts the tightening direction by using a downward-acting clamping force instead of upward. The L-shaped clamping lever applies force downward onto the battery terminal through its free end, reversing the problematic upward motion of conventional flanges during tightening, thereby preventing flange displacement and ensuring proper engagement.
Solution Approach 2:
The patent introduces a vertical dimension to the clamping action by using an L-shaped clamping lever that extends vertically downward from the mounting plate. This dimensional change allows the tightening force to be applied in the vertical direction rather than horizontally, eliminating the flange rising issue while maintaining secure engagement.
2Ease of operation
If the clamping means is exposed without protective enclosure, then access for tightening is easy, but the clamping means is exposed to risks of damage, contamination, or accidental handling
Solution Approach 1:
The protective enclosure is segmented into a fixed base portion integrated with the housing and a movable cover portion that can be independently opened and closed. This segmentation allows the clamping means to be protected during normal operation while remaining accessible when needed, resolving the contradiction between protection and accessibility.
Solution Approach 2:
The cover portion is designed to be movable rather than fixed, allowing it to be opened for tightening operations and closed for protection. This dynamic design enables the system to switch between protected and accessible states, simultaneously addressing both safety and ease of operation requirements.
3Device complexity
If the signal output is positioned at the bottom of the device, then the clamping structure is simplified, but cable connection becomes difficult and requires routing under the battery
Solution Approach 1:
The signal output is repositioned from the bottom (vertical dimension) to the side wall (horizontal dimension) of the housing. This dimensional relocation allows cables to be connected laterally without requiring routing under the battery, simplifying installation while maintaining the straightforward clamping structure.
Solution Approach 2:
The signal output connector is pre-positioned on the side wall in an easily accessible location, allowing cable connections to be made before battery installation or without complex routing. This preliminary positioning of the connector eliminates the need for difficult post-installation cable management.
Data Source
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AI summary
The present invention relates to an electronic measuring device (1) that is intended to be mounted on a vehicle battery (2) and that comprises: an electrical supply input and an electrical supply output (12), the supply input or the supply output being formed by an electrically conductive fastening body designed to tighten around a first axis via the actuation of a fastening means (20) so as to be able to be fastened around a battery terminal; an output of a signal (13) carrying measured values of at least one parameter of an electrical current flowing between the supply input and the supply output, wherein the fastening means is arranged so as to be able to be actuated via a movement around or along a second axis substantially parallel to the first axis.