Inductive Sensor Battery Presence Detection

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Solution Overview

Problem

Traditional methods for detecting battery presence in devices require opening the device enclosure, which is time-consuming, labor-intensive, and prone to human error, especially when dealing with large numbers of devices.

Innovation Solution

A battery presence detector using an inductive sensor to sample an interaction value derived from a galvanized current response caused by the presence of a battery, allowing for detection without opening the device enclosure and enabling separation of devices based on battery presence.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If physical inspection by opening the device enclosure is used to detect battery presence, then detection accuracy is improved, but productivity deteriorates and device damage risk increases

Engineering Contradiction:

Improvebattery presence detection accuracyVSAvoidinspection throughput

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical inspection method (opening the device enclosure) with an inductive sensing system that uses electromagnetic fields to detect battery presence through the enclosure, thereby maintaining detection accuracy while dramatically improving productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an inductive sensor as an intermediary that indirectly detects battery presence by sensing electromagnetic interactions through the enclosure, eliminating the need for direct physical contact or opening the device

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If physical inspection by opening the device enclosure is used to detect battery presence, then detection accuracy is improved, but device damage risk increases

Engineering Contradiction:

Improvebattery presence detection accuracyVSAvoiddevice damage risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical opening and physical handling with non-contact inductive sensing, eliminating the harmful mechanical actions that could damage delicate devices while maintaining accurate battery presence detection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The inductive sensor acts as an intermediary that enables detection without direct contact, preventing physical damage to the device enclosure and internal components while still accurately determining battery presence

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If manual physical inspection is used to detect battery presence, then detection reliability is improved, but loss of time increases

Engineering Contradiction:

Improvedetection reliabilityVSAvoidinspection time per device

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces time-consuming manual inspection with automated inductive sensing that operates at high speed, maintaining reliable detection while reducing inspection time per device from minutes to fractions of a second

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables automatic detection without human intervention, with the inductive sensor autonomously detecting battery presence and the system automatically making separation decisions, eliminating manual labor time while maintaining reliability

Inventive Principle:

Principle #25Self-service

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 solution improves efficiency by eliminating the need for physical inspection, reduces the risk of device damage, and achieves significant labor savings in high-volume device handling scenarios.

Implementation Method 1

sampling an interaction value derived from a galvanic current response caused by a presence of the battery using an inductive sensor

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250044475A1Inductive sensor-based battery presence detection in device enclosures and related methods

Publication Date: 2025.02.06 DISH NETWORK LLC

AI summary

A battery presence detector designed to detect the presence of batteries in a device enclosure without the need to open the enclosure is described. The detection process involves the use of an inductive sensor to sample an interaction value triggered by the presence of the battery within the device. The devices to be checked for battery presence may be placed on a conveyor. The detector may be used with a mechanism for separating the devices based on whether or not a battery is present within them. Examples of devices to be tested include remote controls and cell phones.