Movable Contact Bridge for EV Battery Test Bench Switching
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Solution Overview
Problem
The challenge lies in quickly and safely switching between performance and insulation tests on batteries for electric vehicles, while ensuring reliable transmission of varying electrical loads and maintaining a compact design, due to the numerous plug connections required for power and control lines.
Innovation Solution
A switching device with a support structure and movable contact blocks that allow for easy transition between functional and insulation tests, featuring a bridge element to connect terminals, ensuring safe and efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous separate plug connections are used for power supply, control lines and data lines, then reliable electrical connections can be established, but the device occupies large installation space and switching between test modes becomes complex
Solution Approach 1:
The patent combines multiple separate plug connections (power supply, control lines, data lines) into integrated contact blocks with bridge elements. The first and second contact blocks can be connected in different configurations (first contact position for functional testing, second contact position for insulation testing), merging multiple connection functions into a single compact switching mechanism that reduces installation space while maintaining connection reliability.
Solution Approach 2:
The contact blocks are designed with multi-functionality to serve different testing purposes. The same contact blocks can be configured for functional testing (connecting all terminals) or insulation testing (bridging specific terminals), eliminating the need for separate dedicated connections for each test type and reducing overall installation space requirements.
2Reliability
If separate switching of all battery terminals is performed for functional testing, then complete test coverage is achieved, but quick switching between functional test and insulation test becomes difficult
Solution Approach 1:
The patent employs dynamic switching between two contact block configurations. The contact blocks can be quickly repositioned between first contact position (for functional testing with complete terminal coverage) and second contact position (for insulation testing with bridged terminals). This dynamic reconfiguration enables rapid mode switching while maintaining complete test coverage for each respective test type.
Solution Approach 2:
The contact blocks are pre-configured with bridge elements that enable immediate switching between test modes. The bridge elements are positioned and structured to automatically establish the required connection configurations when contact blocks are moved between positions, eliminating the need for manual reconfiguration and reducing switching time between functional and insulation testing.
3Reliability
If robust components are provided to transmit high voltages and currents safely, then transmission reliability is improved, but the device design becomes less compact
Solution Approach 1:
The patent merges multiple connection functions into integrated contact blocks that handle both high voltage and high current transmissions simultaneously. The contact blocks with bridge elements consolidate what would otherwise require separate robust components for power supply, control, and data lines, achieving safe electrical load transmission while maintaining a compact device volume.
Data Source
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AI summary
Switching device for a test stand for electrical components, comprising a support structure (4, 4'), a first contact block (6, 6') attached to the support structure (4, 4'), the first contact block (6, 6') having first terminals (8, 8') for connecting a battery to be tested, the first contact block (6, 6') having one or more second terminals (10, 10') for connecting a high-voltage tester, and the first contact block (6, 6') having third terminals (12, 12') for connecting a functional tester, and a second contact block (14, 14'), the second contact block (14, 14') being a contact bridge (14, 14'), the second contact block (14, 14') being movable relative to the first contact block (6, 6'), the second contact block (14, 14') being in a first contact position connecting the first terminals (8, 8') connects to at least one second terminal (10, 10'), wherein the first terminals (8,8') in the first contact position by means of a bridge element (16) of the first contact block (6, 6') and connected via the bridge element (16) to the at least one second terminal (10, 10') or in a first contact position connects the first terminals (8') with the second terminals (10'), wherein the second contact block (14, 14') in a second contact position connects the first terminals (8, 8') with the third terminals (12, 12').