Profiling Connector with Elastic Probe for Battery Test Wear Reduction
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Solution Overview
Problem
Standard connectors used for testing battery modules are prone to damage from frequent plugging and unplugging, and manual operation is difficult, leading to finger injuries and high replacement costs.
Innovation Solution
A test tool with a profiling connector featuring an elastic probe and guide pillars for easy insertion, along with a gripping mechanism to stabilize the connection, reducing friction and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard connectors are used for battery module testing, then the testing function is achieved, but the connectors are easily damaged from frequent plugging and unplugging
Solution Approach 1:
The patent introduces an elastic probe as an intermediary element between the connector and the socket. The elastic probe deforms elastically during insertion and maintains continuous contact pressure, converting the rigid sliding friction of traditional connectors into elastic abutment contact. This mediator absorbs mechanical stress from frequent plugging and unplugging operations, preventing damage to the connector while maintaining reliable electrical connection for battery module testing
Solution Approach 2:
The patent changes the physical state and mechanical properties of the connector by incorporating an elastic probe that can deform and recover. The elastic probe undergoes cyclic elastic deformation during plugging and unplugging operations, transforming the connector from a rigid structure susceptible to wear into a flexible structure that absorbs mechanical energy. This parameter change in material behavior (from rigid to elastic) resolves the contradiction between durability and operational ease
2Reliability
If standard connectors are used for battery module testing, then voltage and temperature monitoring is enabled, but manual operation causes finger injuries due to difficulty in plugging and unplugging
Solution Approach 1:
The elastic probe serves as a protective intermediary that absorbs the mechanical harm caused during manual operation. By designing the connector with an elastic probe that deforms during insertion, the patent creates a buffer zone that reduces the force transmission to the operator's fingers. The elastic abutment mechanism prevents the hard sliding contact that causes finger injuries, while still enabling reliable voltage and temperature monitoring of the battery module
Solution Approach 2:
The patent converts the potentially harmful sliding friction and mechanical impact into beneficial elastic deformation. The elastic probe is designed to undergo controlled deformation during plugging and unplugging, transforming the harmful mechanical stress into useful elastic energy absorption. This converts the harm (finger injuries from difficult operation) into a benefit (reduced operational force requirements and improved safety) while maintaining the monitoring function
3Productivity
If standard connectors are used for battery module testing, then the testing process is completed, but replacement costs are high due to frequent damage
Solution Approach 1:
The elastic probe is designed to be self-healing through elastic recovery. After each plugging and unplugging operation, the elastic probe automatically returns to its original shape and position, maintaining its structural integrity and electrical connection capability. This self-service characteristic eliminates the need for frequent replacements, reducing both maintenance costs and downtime, while ensuring continuous testing efficiency for battery module voltage and temperature monitoring
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 profiling connector reduces connector damage and operator injuries while extending service life and lowering maintenance costs by converting sliding friction to elastic abutment, facilitating safe and efficient battery testing.
Implementation Method 1
an elastic probe is provided in a jack of the profiling connector, and once the profiling connector is inserted into the socket to be detected and plugged, the elastic probe elastically abuts against the probe of the socket, thus changing the original sliding friction between the probe of the connector and the probe of the socket into elastic abutment
Data Source
AI summary
A test tool includes an operating portion with a first end used for hand-holding, and a profiling connector adapted to a socket to be detected and plugged. An elastic probe is provided in a jack of the profiling connector, and the profiling connector is arranged at a second end of the operating portion opposite to the first end. The profiling connector is configured to be inserted into the socket by holding the operating portion with hand, with the elastic probe abutting against and electrically connected with a probe in the socket.