Hi-Pot Contact Test Device for Battery Probe Verification
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Solution Overview
Problem
Conventional hi-pot test devices fail to ensure reliable connection between probes and battery terminals during high-potential tests, leading to unreliable test results, especially in high-capacity and high-output battery packs used in hybrid and electric vehicles.
Innovation Solution
A contact test device and system that includes a control unit, switch units, and continuity detection units to verify the connection between probes and battery terminals before performing the hi-pot test, ensuring that the probes are correctly connected to prevent false pass results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional hi-pot test device is used without additional contact detection, then the test device structure remains simple, but the reliability of the test cannot be ensured because the probe connection status cannot be detected
Solution Approach 1:
The test system is segmented into two independent functional modules: the original hi-pot test device and the contact test device. Each module performs its specific function independently, allowing the contact detection capability to be added without modifying the complex hi-pot test circuitry, thus improving reliability while keeping the overall structure manageable through functional separation
Solution Approach 2:
A contact test device is introduced as an intermediary component between the operator and the hi-pot test device. This intermediary includes continuity detection units that indirectly detect probe connection status by measuring electrical continuity through the probes, providing reliable connection information without requiring direct modification of the hi-pot test device structure
2Reliability
If the hi-pot test device operates without contact detection, then the operation is simple and fast, but false pass results may occur when probes are not properly connected
Solution Approach 1:
The contact test device performs connection detection as a preliminary action before the actual hi-pot test is executed. The continuity detection units check probe connection status in advance, and only when proper connection is confirmed does the system proceed to the hi-pot test, preventing false pass results while maintaining operational simplicity through automated preliminary verification
Solution Approach 2:
The contact test device provides immediate feedback regarding probe connection status to the operator. The continuity detection units generate detection results that are displayed to indicate whether probes are properly connected, giving operators real-time feedback to ensure correct setup before testing, thus improving test accuracy without significantly complicating the operation
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 system reliably detects and ensures proper connection of probes to battery terminals, enhancing the reliability and safety of the hi-pot test by preventing tests from being conducted without actual contact, thus ensuring accurate and secure high-voltage applications.
Implementation Method 1
a first closed loop connected to the first line, and including first to third switch units connected to each other in series, a direct current (DC) voltage source and a first continuity detection unit
Data Source
AI summary
A contact test device for a hi-pot test includes: a contact test device connected to a hi-pot test device in parallel by lines branched from first and second lines of the hi-pot test device by being connected to first and second terminals of a battery through first and second probes, respectively, and having third and fourth probes directly connected to the first and second terminals, wherein the contact test device includes: a first closed loop including first to third switch units, a direct current (DC) voltage source and a first continuity detection unit; a second closed loop including fourth to sixth switch units, the DC voltage source and a second continuity detection unit; and a control unit controlling turning the first to sixth switch units on and off and detecting a continuity signal of each of the first and second continuity detection units.