Resistor Assembly Welding for Battery Sensor Mechanical Load Resistance
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Solution Overview
Problem
Existing resistor assemblies for battery sensors in vehicles face challenges in withstanding mechanical loads, vibrations, and temperature fluctuations, particularly in ensuring a reliable connection between connection elements and the measuring resistor, which is crucial for accurate battery condition monitoring.
Innovation Solution
A resistor assembly production method involving welding of connection elements to the resistance element without additives, using protrusions with multiple mounting positions for flexible alignment and enhanced strength, allowing for a strong, flexible connection that can absorb mechanical loads and maintain reliability under varying conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connection elements are connected to the measuring resistor by soldering or resistance brazing using additional connecting material, then the connection can be established between components, but the connection strength is insufficient to withstand mechanical stresses like vibrations or shocks during vehicle operation
Solution Approach 1:
The invention removes the additional connecting material (solder or brazing material) from the connection structure. Instead of using separate connecting materials to join the connection element to the measuring resistor, the patent directly welds the connection element to the resistor terminal, eliminating the intermediate layer and creating a more robust monolithic connection that better withstands mechanical stresses.
Solution Approach 2:
The invention merges the connection element and measuring resistor into a single welded structure. By directly welding these components together without intermediate connecting materials, the patent creates an integrated assembly where the connection joint becomes as strong as or stronger than the base materials themselves, resolving the strength deficiency of traditional soldered connections.
2Adaptability or versatility
If the second connection element is rigidly fixed to the measuring resistor, then the connection stability is improved, but the ability to flexibly align the connection element to absorb tensile forces acting on the ground cable is reduced
Solution Approach 1:
The invention introduces a degree of flexibility into the connection structure by allowing the connection element to be angularly adjustable relative to the measuring resistor while maintaining a secure welded connection. This dynamic capability enables the assembly to adapt to varying tensile force directions from the ground cable, absorbing mechanical loads more effectively while preserving connection integrity through the rigid weld joint.
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 method provides a robust and flexible connection that withstands vehicle operational loads, ensuring reliable battery condition monitoring by maintaining a strong, integral connection between the connection elements and the resistance element, even under mechanical stress and temperature fluctuations.
Implementation Method 1
welding the first connection surface to the second connection surface by at least partially melting and subsequently hardening the first connection surface and/or the second connection surface
Implementation Method 2
welding the first connection surface to the second connection surface by at least partially melting and subsequently hardening the first connection surface and/or the second connection surface
Data Source
Figure 1~2
Figure 3a~3c
Figure 4~5e
AI summary
The invention relates to a method for manufacturing a resistor assembly (24) for a battery sensor (10), comprising a first connection element (12), a second connection element (16), and a resistor element (20) that electrically connects the first connection element (12) and the second connection element (16), wherein the first connection element (12) and/or the second connection element (16) has a first connection surface (30a, 30b) and the resistor element (20) has at least one second connection surface (32a, 32b), comprising the following steps: - providing the first connection element (12) and/or the second connection element (16) and the resistor element (20), - aligning the first connection element (12) and/or the second connection element (16) so that the first connection surface (30a, 30b) rests against a second connection surface (32a, 32b), and - welding the first connection surface (30a, 30b) with the second connection surface (32a,32b) by at least partially melting and subsequently hardening the first contact surface (30a, 30b) or the second contact surface (32a, 32b). The invention further relates to a resistor assembly (24) produced by this method.