Integrated MSD Connector Assembly for Safe Battery Test Access
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Solution Overview
Problem
Existing power battery test devices face challenges in safely measuring high current and voltage due to limited space and structural weaknesses in MSD connectors, leading to injury risks and inconvenient separate components.
Innovation Solution
An integrated MSD connector test device is designed with a housing, MSD connector, and extended cables for voltage and current measurement, incorporating fuses for protection and a compact, portable structure for easy handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the MSD connector housing is modified to extend conductive wires and test ports out through a hole, then test interfaces are available for measurement, but the housing is not strong enough to withstand long-term stress and has limited space for high current applications
Solution Approach 1:
The device is segmented into distinct functional components: the MSD connector housing, the cable assembly with conductive wires, and the test port interface. This segmentation allows the housing to maintain its original structural integrity while the cable assembly provides the extended test interfaces, resolving the contradiction between accessibility and strength.
2Adaptability or versatility
If a separate cable is extended out from the connector for voltage test, then voltage measurement is enabled, but the design is not integrated and has two separate components that are inconvenient to carry
Solution Approach 1:
The voltage test cable and current test cable are merged into a single integrated cable assembly that connects to the MSD connector. This consolidation combines multiple test functions into one unified component, enabling both voltage and current measurements while improving portability and reducing the number of separate components.
3Ease of operation
If the test ports are exposed outside the housing, then measurement access is provided, but there is no fuse protection and short circuits could electrically shock the operator
Solution Approach 1:
Fuse protection is built into the cable assembly before the test ports, providing preliminary safety protection. The fuses are pre-installed in the conductive wires to prevent electrical shocks and short circuits before they can affect the operator or equipment, resolving the contradiction between accessibility and safety.
Data Source
AI summary
An integrated MSD connector test device including: a housing; an MSD connector housed in the housing and having a first polarity contact and a second polarity contact, wherein the second polarity contact includes two contact portions separated from each other; a cable extending at least partially outside of the housing, two ends of the cable being electrically connected to the two contact portions respectively; and a first polarity port and a second polarity port accessible from outside of the housing, the first polarity port being electrically connected to the first polarity contact, and the second polarity port being electrically connected to one of the contact portions, wherein the first polarity is a positive or negative, and correspondingly, the second polarity is a negative or positive.