Safety Connector Layout for Accurate Battery Jump-Start Detection
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Solution Overview
Problem
Existing safety connectors for vehicle batteries lack an efficient internal structure layout, leading to unsatisfactory installation efficiency and detection accuracy, which compromises the safety of power transmission.
Innovation Solution
A safety connector with a housing, control board, power supply connection member, and cable assembly, featuring multiple cables connected to the control board, ensuring stable and efficient power transmission through a rational structural layout, including a concave part on the control board to accommodate the power supply connection member and a communication terminal for monitoring voltage, current, and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional safety connector structure is used, then the device is simple to manufacture, but the installation efficiency and detection accuracy are unsatisfactory
Solution Approach 1:
The cable assembly is divided into multiple independent cables (first cable, second cable, third cable) with distinct functions: power transmission, voltage detection, and current detection. This segmentation allows each cable to be optimized for its specific function, improving overall installation efficiency and detection accuracy while maintaining manufacturing simplicity through standardized cable connectors.
Solution Approach 2:
The patent introduces a spatial dimension to the internal structure by arranging cables and connection members in specific three-dimensional positions within the housing. The power supply connection member, electrical connection member, and detection circuits are positioned at different heights and angles, creating an optimized spatial layout that improves both installation efficiency and detection accuracy without significantly increasing manufacturing complexity.
2Measurement precision
If multiple cables are used for power and detection, then detection accuracy improves, but the risk of electric leakage increases
Solution Approach 1:
The control board serves as an intermediary between the multiple cables and the detection circuits. It processes signals from the voltage detection cable and current detection cable separately, then integrates this information to control the power transmission through the power supply connection member. This intermediary structure enables accurate detection while maintaining safety by providing centralized control and monitoring of all electrical connections.
Solution Approach 2:
Different cables are assigned different functional qualities: the power supply cable is optimized for high-current transmission with appropriate gauge and insulation, while the detection cables are optimized for signal integrity with shielded construction. This local quality differentiation allows each cable to perform its specific function optimally while minimizing the risk of electric leakage through appropriate material selection and connection design.
3Power
If the control board is positioned centrally, then power transmission is stable, but the structural stability and safety are compromised
Solution Approach 1:
The control board is nested within the housing structure at a position that allows it to be centrally located for power transmission stability, while the housing itself provides the primary structural support and safety enclosure. The connection members are nested within the housing and positioned to engage with the control board through standardized interfaces, creating a hierarchical structure where the housing provides structural stability and the control board provides power transmission stability without compromising either function.
Data Source
AI summary
A safety connector includes a housing, a cable assembly and an electrical connection assembly. A control board is disposed inside the housing, and a power supply connection member is disposed on a side of the housing. The cable assembly includes at least one first cable and at least two second cables. The electrical connection assembly includes a first electrical connection member and a second electrical connection member. The power supply connection member is connected to the first electrical connection member through the at least one first cable, and the power supply connection member, the control board, and the second electrical connection member are sequentially connected through the at least two second cables.