Power Relay Device With Segmented Terminal Cover For Battery Testing
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Solution Overview
Problem
In vehicle assembly plants, when batteries are installed in consoles instead of engine compartments, the battery terminals cannot be easily removed, leading to continuous connection during electric testing, which decreases the battery's charge level.
Innovation Solution
A power relay device with a main device body, terminal cover, and holding unit that allows temporary disconnection of power supply to prevent constant charging, using a connection terminal that can be electrically disconnected from either the power source or load terminal, and an external connection medium to supply power when needed for testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery is installed in the console for vehicle assembly plant testing, then the battery can be positioned in the vehicle interior, but the battery terminals cannot be easily removed leading to continuous power supply and charge level decrease
Solution Approach 1:
The power relay device is divided into a main device body and a separable terminal cover. The terminal cover can be detached from the main device body, allowing the battery terminals to be easily connected or disconnected by simply removing or attaching the terminal cover, thus preventing continuous power supply when testing is not needed.
Solution Approach 2:
The holding unit provides dynamic control over the connection state between the terminal cover and main device body. It can selectively set a temporary holding state (disconnected) or final holding state (connected), enabling flexible adjustment of power supply status according to testing requirements, thereby avoiding unnecessary energy consumption.
2Productivity
If the battery terminals are continuously connected for electric testing, then testing can be performed, but the battery charge level decreases due to constant power supply
Solution Approach 1:
The power supply to the electric component is made periodic rather than continuous. The terminal cover is connected only during testing periods and disconnected during non-testing periods. The holding unit ensures stable connection during testing while allowing easy disconnection afterward, enabling testing functionality while minimizing energy loss.
3Ease of operation
If the terminal cover is made separable for easy connection/disconnection, then battery terminals can be easily removed, but the connection stability may be compromised
Solution Approach 1:
The holding unit dynamically adjusts the connection state between terminal cover and main device body. It provides a temporary holding state for easy disconnection and a final holding state for stable connection. The holding unit ensures reliable electrical connection during testing while allowing easy transition to disconnected state when testing is complete.
Data Source
AI summary
A power relay device is provided that relays power from a power source and supplies the power to an electric component. The power relay device includes a main device body, a terminal cover, and a holding unit. The main device body includes a power source terminal electrically connected to the power source and a load terminal electrically connected to the electric component. The terminal cover includes a connection terminal electrically connectable to a connected subject that is one of the power source terminal and the load terminal. The holding unit selectively sets a temporary holding state in which the connection terminal is electrically disconnected from the connected subject or a final holding state in which the connection terminal is electrically connected to the connected subject.