Deep-Drawn Battery Terminal Clamp for Secure Pole Hold
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Solution Overview
Problem
Existing methods for manufacturing battery terminal clamps are not cost-effective and do not ensure a stable hold on vehicle battery poles, requiring improvements in production efficiency and reliability.
Innovation Solution
A method involving a deep-drawing process to form a base body with a clamping section and receptacles for a clamping device, where the receptacles are shaped by bending and caulking to create a closed channel, allowing for easy production and secure clamping, with anti-twist, anti-displacement, and captive devices to enhance stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional bending or deep-drawing processes are used to manufacture battery terminal clamps, then the production process is established, but the manufacturing cost is high and production efficiency is low
Solution Approach 1:
The manufacturing process is segmented into distinct operations: providing a flat base body, forming the clamping section by deep-drawing, and forming receptacles by bending sections and riveting projections. This segmentation allows each step to be optimized independently, improving overall production efficiency while controlling costs.
Solution Approach 2:
The flat base body is prepared in advance with specific geometric features before the deep-drawing and forming processes. This preliminary preparation enables subsequent operations to proceed more efficiently and reduces manufacturing complexity, thereby lowering costs while maintaining high productivity.
2Reliability
If the battery terminal clamp uses a simple design for easy manufacture, then manufacturing cost is reduced, but the hold stability on battery terminals is insufficient
Solution Approach 1:
The clamp features locally optimized structures: the clamping section has a specific geometric shape formed by deep-drawing to ensure stable hold, while receptacles are formed by bending and riveting to provide secure engagement for clamping devices. These localized quality enhancements ensure reliability without requiring complex overall design, maintaining ease of manufacture.
Solution Approach 2:
Multiple functions are merged into a single component: the base body provides structural support, the deep-drawn clamping section ensures stable hold on battery terminals, and the formed receptacles secure clamping devices. This merging reduces the number of separate parts needed, simplifying manufacturing while ensuring reliability through integrated design.
3Reliability
If the receptacles are formed by bending and riveting to create closed channels, then the clamping device engagement is secure, but the manufacturing process becomes more complex
Solution Approach 1:
The receptacle formation is segmented into bending a section of the base body and subsequently riveting a projection into a recess. This segmentation creates closed channels that securely engage clamping devices while using standard forming and joining operations, avoiding the need for complex specialized processes.
Solution Approach 2:
The base body itself provides the material for forming receptacles through bending and riveting operations. The structure is self-contained, with projections and recesses formed from the base material, eliminating the need for separate components or complex assembly processes, thereby reducing overall manufacturing complexity while ensuring secure engagement.
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 method enables cost-effective and efficient production of battery terminal clamps that provide a reliable, secure hold on battery poles, ensuring stable power supply and measurement while simplifying manufacturing and assembly processes.
Implementation Method 1
forming the clamping section by a deep-drawing process
Implementation Method 2
the receptacles are produced by bending a section of the base body
Implementation Method 3
subsequently riveting a projection provided on the section into a recess of the base body
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a method for manufacturing a battery terminal clamp (10), in particular for a vehicle battery in a vehicle, wherein the battery terminal clamp (10) has a base body (14) with a clamping section (16) for a battery terminal of a battery, in particular a vehicle battery, and at least one receptacle (18) provided on the clamping section (16) for a clamping means (20), wherein the clamping section (16) at least partially encloses a receiving space (24), in particular a substantially cylindrical space, for the battery terminal of the battery in the circumferential direction (U) and has an interruption (26) with mutually facing edges (30) in the circumferential direction (U), and wherein a receptacle (18) is provided on each of the edges (30) of the clamping section (16), comprising the following steps: - providing a flat base body (14), - forming the clamping section (16) by a deep-drawing process, and - forming the receptacles (18) by a forming process.The invention further relates to a battery terminal clamp (10) produced by this method and to a battery sensor (12) with such a battery terminal clamp (10).