Profiling Connector With Elastic Probe for Battery Test Socket Wear
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Solution Overview
Problem
Standard connectors used for testing the working voltage and temperature of battery modules are prone to damage from frequent plugging and unplugging, and are difficult to operate manually, leading to finger injuries and reduced service life.
Innovation Solution
A test tool with a profiling connector that includes an elastic probe and guide pillars, allowing for easy insertion and secure connection to the socket, reducing wear and tear, and preventing finger injuries during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard connectors are used for testing battery modules, then the testing function is achieved, but the connector is easily damaged due to frequent plugging and unplugging
Solution Approach 1:
The connector is divided into two separate parts: a fixed profiling connector attached to the test tool and a removable socket connected to the battery module. This segmentation allows the socket to be easily plugged and unplugged without damaging the main connector structure, resolving the contradiction between durability and ease of operation.
Solution Approach 2:
The profiling connector acts as an intermediary component with an elastic probe that provides mechanical cushioning during connection. The elastic probe deforms to absorb insertion forces, protecting the connector from damage while maintaining reliable electrical contact, thus improving both durability and ease of operation.
2Reliability
If standard connectors are used for testing, then voltage and temperature monitoring is enabled, but finger injuries occur due to difficult manual operation
Solution Approach 1:
By separating the connector into a fixed profiling connector and a removable socket, the operation is simplified to attaching/detaching the socket rather than manipulating the entire connector assembly. This reduces the risk of finger injuries while maintaining testing accuracy through reliable electrical contacts.
Solution Approach 2:
The elastic probe in the profiling connector serves as a mechanical intermediary that cushions the connection force, reducing the manual effort required and minimizing the risk of operator injury during plugging and unplugging operations.
3Reliability
If profiling connector with elastic probe is used, then connector service life is extended, but device complexity increases
Solution Approach 1:
The elastic probe is introduced as a simple intermediary element within the jack structure. It provides cushioning and protection against damage through its elastic deformation properties, extending connector service life without significantly increasing overall device complexity.
Solution Approach 2:
The elastic probe changes the mechanical parameters of the connector by introducing elasticity and compliance. This allows the connector to absorb insertion forces through deformation rather than rigid contact, extending service life while maintaining a relatively simple structural design.
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 with an elastic probe and guide pillars effectively extends the service life of the connector, reduces finger injuries, and simplifies the testing process by facilitating easy and secure connections.
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
Implementation Method 2
changing the original sliding friction between the probe of the connector and the probe of the socket into elastic abutment
Data Source
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AI summary
A test tool with a profiling connector and a battery testing method are provided. The test tool with a profiling connector comprises: an operating portion 1, a first end of the operating portion 1 being used for hand-holding; and a profiling connector 2 adapted to a socket 7 to be detected and plugged, where an elastic probe 21 is provided in a jack of the profiling connector 2, and the profiling connector 2 is arranged at a second end of the operating portion 1 opposite to the first end. The profiling connector 2 can be inserted into the socket 7 by holding the operating portion 1 with hand, with the elastic probe 21 abutting against and electrically connected with a probe in the socket 7. The test tool with a profiling connector above can facilitate inserting the connector into the socket by the staff and avoid injury to fingers while changing the sliding friction between the probe in existing connectors and the probe in the socket into elastic abutment, thereby effectively avoiding damage to the profiling connector caused by repeated plugging and unplugging and improving the service life.