Battery Testing Contact with Crown Spring and Segmented Prongs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery testing systems face challenges in achieving reliable high-current contact while maintaining separate voltage measurement paths, leading to potential high resistance and temperature issues during testing.
Innovation Solution
The design incorporates a base with a crown spring and a coil spring surrounding a rod, which provides a robust electrical contact for high-current applications, combined with a contact sheet featuring multiple prongs for multi-point contact, and an optional voltage probe for independent voltage measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single contact point is used for high-current testing, then the current path is simple, but the contact resistance increases and temperature issues arise
Solution Approach 1:
The contact sheet is divided into multiple prongs (typically 3-5) that contact the battery terminal at different points simultaneously. This segments the current path across multiple contact points, reducing the current density at each individual point and thereby reducing contact resistance and temperature generation at each contact interface.
2Measurement precision
If separate voltage measurement paths are added, then voltage measurement accuracy improves, but the device complexity increases
Solution Approach 1:
The voltage probe is positioned within the hollow interior of the rod, utilizing the empty space inside the rod structure. This nested arrangement allows the voltage measurement function to be added without increasing the overall footprint or requiring additional external components, thereby minimizing the increase in device complexity while achieving separate voltage measurement capability.
3Power
If a robust high-current contact structure is used, then current handling capability improves, but the contact force control becomes difficult
Solution Approach 1:
The coil spring provides a dynamic, elastic contact force that automatically adjusts to the battery terminal surface irregularities and maintains optimal contact pressure during testing. This dynamic spring mechanism replaces rigid mechanical fastening, making contact force control easier while maintaining robust electrical connection for high current handling.
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
This configuration ensures reliable high-current contact with reduced resistance and temperature issues, while allowing for accurate separate voltage measurements, enhancing the overall efficiency and accuracy of battery testing.
Implementation Method 1
a crown spring received in the base, a rod or probe or plunger received in the crown spring and another type of spring, such as a coil spring or a gas spring, which pushes or pulls the rod, plunger or probe
Implementation Method 2
The crown spring provides good electrical contact between the rod and the base for forming a circuit suitable for high-current load on the test item
Data Source
AI summary
An electrical contact device includes a tubular element, a crown spring in the tubular element, a solid or hollow cylinder slideably received in the crown spring and a coil spring engaged with the cylinder for applying force while the cylinder is pressed against a test item and for returning the cylinder to a relaxed position. The crown spring holds the cylinder in the tubular element and allows the cylinder to slide back and forth while providing electrical connectivity between the cylinder and the tubular element. An electrical contact device includes a rod-shaped probe having a contact end and a contact sheet fixed to the probe, where the contact sheet has a plurality of prongs bent over the contact end of the probe for providing a plurality of contact points between the probe and a test item.