Multi-Orientation Cable Connector for Battery Tester
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Solution Overview
Problem
There is a need for improved convenience in connecting cables to portable battery testers for enhanced handling and positioning during battery test operations.
Innovation Solution
A battery tester system that includes a cable pod and housing with mating parts allowing manual adjustment and securement in multiple orientations, enabling easy attachment and detachment without tools, and providing Kelvin connections for accurate four-terminal sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cable connector is designed for fixed orientation attachment to battery tester, then connection reliability is improved, but ease of operation deteriorates due to limited positioning flexibility
Solution Approach 1:
The connector design transitions from a fixed orientation to a dynamic multi-orientation system. The cable pod incorporates features that allow it to be securely attached to the battery tester housing in multiple predetermined orientations (e.g., 0°, 90°, 180°, 270°), enabling the user to dynamically adjust the cable position based on handling needs while maintaining reliable electrical connections in any orientation.
2Ease of operation
If a cable pod allows manual reorientation in multiple positions, then ease of operation is improved, but device complexity increases due to additional mating parts
Solution Approach 1:
The connector employs asymmetric mating features including positioning protrusions on the cable pod that correspond to recesses in the housing, and complementary asymmetric engagement surfaces. This asymmetric design enables multiple predetermined orientations while actually reducing overall complexity compared to a fully adjustable mechanism, as the asymmetry guides the user to correct orientations without requiring complex sensors or actuators.
3Measurement precision
If Kelvin connections are implemented for four-terminal sensing, then measurement precision is improved, but device complexity increases due to additional connection requirements
Solution Approach 1:
The connector design merges the mechanical attachment function with the electrical connection function into a single integrated assembly. The same mating parts that secure the cable pod to the housing also establish the Kelvin connections for four-terminal sensing, eliminating the need for separate mechanical and electrical connection mechanisms and thereby reducing overall device complexity while maintaining measurement precision.
Data Source
AI summary
A battery tester including a battery tester cable, a cable pod coupled to an end of the battery tester cable, and a battery tester housing including a cavity configured to receive the cable pod. The cable pod and the cavity include mating parts configured to mate the cable pod within the cavity in at least two different preset orientations. In some examples, the orientations are changeable and securable manually.