Battery Test Bench Contact Bridge for Fast HV Test Switching
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Solution Overview
Problem
The challenge lies in developing a switching device for test stands that enables a simple, safe, and fast change between functional and insulation tests for electric batteries, while ensuring reliable and safe transmission of electric power, particularly in a compact design, given the wide voltage and current ranges involved in these tests.
Innovation Solution
A switching device with a support structure and movable contact blocks, where one contact block bridges connections during a first position for insulation testing and connects them individually in a second position for functional testing, utilizing a bridge element and conductive strips to manage multiple connections efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate switching is performed for each connection during power testing, then functional reliability is ensured, but switching time increases and productivity decreases
Solution Approach 1:
Multiple individual connection switchings are merged into a single collective switching operation. The contact block is designed to simultaneously switch all connections between the battery and test equipment, transforming forty separate switching operations into one unified action, thereby dramatically improving productivity while maintaining reliability
Solution Approach 2:
The contact block serves multiple functions: it simultaneously establishes or breaks all electrical connections for different test modes (power testing, insulation testing). This multi-functional component eliminates the need for separate switching mechanisms for each connection, resolving the contradiction between reliable individual switching and fast collective switching
2Ease of operation
If connections are bridged for insulation testing, then test configuration is simplified, but device complexity increases due to additional bridge elements
Solution Approach 1:
The bridge element is integrated into the contact block structure itself, merging the bridging function with the existing switching mechanism. This integration adds minimal complexity while enabling simplified test configuration, as the same contact block that switches connections also provides bridging capability when needed
3Reliability
If robust components are used to transmit high electric power, then reliability and safety improve, but installation space increases
Solution Approach 1:
The contact block design nests multiple functional elements within a compact structure. Connections, contact elements, and bridge elements are arranged in a space-efficient configuration that accommodates high power transmission requirements while minimizing overall device volume, thus resolving the contradiction between robustness and compactness
Data Source
AI summary
A switching device for a test stand for electrical components has a support structure and a first contact block attached thereto. The first contact block has first connections for connecting a battery to be tested; one or more second connections for connecting a high-voltage tester; and third connections for connecting a function tester. A second contact block that is a contact bridge and is movable relative to the first contact block is included. The second contact block, in a first contact position, connects first connections to at least one second connection. The first connections are bridged in the first contact position by a bridge element of the first contact block and connected to at least one second connection via the bridge element or, in a first contact position, connects first connections to second connections, wherein the second contact block, in a second contact position, connects first connections to third connections.