Busbar Connector Lock Indicator for Assembly Verification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection devices for battery modules in electric vehicles lack a reliable means to confirm proper locking of busbars to terminals, making it difficult to ensure correct electrical connections, especially in automated assembly lines.
Innovation Solution
A connection device with a housing, lock, and visual locking indicator, featuring a QR code pattern that is only exposed when the lock is in the locking configuration, allowing for easy detection of proper assembly through a reading device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple snap-on connection device is used to connect busbar to terminal, then the ease of manufacture and assembly is improved, but the ability to confirm proper locking and connection reliability deteriorates
Solution Approach 1:
The patent uses visual indicators with different colors or patterns on the lock indicator element to show different connection states. When the busbar is properly connected, the indicator displays a specific visual pattern (e.g., green color or checkmark pattern), while improper connection shows a different pattern (e.g., red color or warning symbol). This allows operators to quickly verify proper assembly without complex measurement tools.
Solution Approach 2:
The patent introduces an intermediary indicator mechanism between the lock arms and the connection state. The indicator element is mechanically linked to the lock arms through a transmission mechanism (such as gears, linkages, or cam-follower systems) that converts the mechanical locking action into a visible signal. This intermediary translates the internal locking state into an externally observable condition.
2Device complexity
If no visual indicator is provided on the connection device, then the device complexity is reduced, but the ease of detecting proper assembly deteriorates
Solution Approach 1:
The connection device performs self-verification through the visual indicator system. The indicator automatically changes state based on the locking condition, eliminating the need for external measurement tools or complex detection systems. The device itself provides the information needed to verify proper assembly, making the detection process simple and intuitive.
Solution Approach 2:
The patent employs color-coded visual indicators that change appearance based on connection status. Proper connection may display green or a checkmark pattern, while improper connection shows red or a warning symbol. This uses human visual perception to simplify detection, requiring no additional equipment beyond basic vision.
3Measurement precision
If automated assembly line detection is required for connection verification, then the measurement precision can be improved, but the productivity and assembly speed deteriorates
Solution Approach 1:
The patent replaces complex mechanical measurement and verification systems with a simplified visual indicator system that can be quickly scanned by operators or simple optical sensors. Instead of using precision measurement devices to verify connection parameters, the system uses a mechanical-to-visual translation mechanism that provides sufficient verification information rapidly, maintaining high assembly speed while ensuring adequate connection quality.
Solution Approach 2:
The visual indicator creates a simplified copy or representation of the connection state that is easy to read and verify. Rather than measuring actual connection forces or positions with precision instruments, the system produces a visual copy (indicator position, color, or pattern) that correlates with proper assembly, enabling rapid verification without detailed measurement.
Data Source
AI summary
A device for connecting an electrical conductor to an electrical connector, the electrical conductor being provided with a pair of notches, comprises a lock formed by two arms that are able to be moved away from one another and close back over the second element in order to be accommodated in the notches thereof and to place the lock in the locking configuration. The device comprises a visual locking indicator formed of at least one pattern. The visual locking indicator is entirely exposed only when the lock is in the locking configuration.