Shunt Resistor Rotation Blocking for Battery Sensors
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Solution Overview
Problem
Conventional battery condition detection sensors face inefficiencies in assembly and reliability due to harness rotation during installation and loosening from vibrations, and existing solutions increase sensor size and complexity.
Innovation Solution
A battery condition detection sensor with a shunt resistor featuring insertion recesses and protrusions or wide portions with rotation-blocking capabilities, allowing secure fixation and orientation of the wire harness without additional components, enhancing assembly efficiency and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coupling member is formed integrally with a current sensor and fixed to a battery terminal, then electrical connection is achieved, but the wire harness may rotate during assembly and loosen under vibrations
Solution Approach 1:
The shunt resistor is designed with an asymmetric structure featuring a rotation-blocking protrusion that prevents the wire harness from rotating during assembly and under vibration. This asymmetric geometric feature ensures reliable connection without requiring additional symmetric fastening components.
2Reliability
If a clamp portion with a pair of fingers is added to prevent rotation of the wire harness, then rotation blocking is achieved, but the size and number of component parts increase
Solution Approach 1:
The rotation-blocking function is merged into the shunt resistor itself by integrating a rotation-blocking protrusion directly on the shunt resistor body. This eliminates the need for separate clamp portions or finger-like components, reducing the total number of parts while maintaining rotation blocking capability.
Solution Approach 2:
The shunt resistor is designed to serve multiple functions: electrical measurement (its primary function) and rotation blocking (an additional function). By incorporating the rotation-blocking protrusion, the shunt resistor becomes a multi-functional component that eliminates the need for dedicated rotation-prevention parts.
3Reliability
If additional components are added to block rotation of the wire harness, then rotation prevention is improved, but the sensor size increases and layout flexibility is reduced
Solution Approach 1:
The rotation-blocking protrusion is integrated directly onto the shunt resistor body, merging the rotation prevention function into the existing sensor structure. This approach prevents harness rotation without adding external components that would increase the overall sensor volume or protrude beyond the battery.
Data Source
AI summary
A battery condition detection sensor (1) for measuring characteristics of a battery (101) includes an electrically conductive battery post terminal (12) and a shunt resistor (13). The battery post terminal (12) is mounted to a battery post (102) provided in the battery (101). The shunt resistor (13) is electrically connected to the battery post terminal (12). The shunt resistor (13) is configured such that a connection terminal (52) of a wire harness (51) can be fixed thereto. The shunt resistor (13) has a rotation-blocking portion (inner walls of the insertion holes (15a, 15b)) for blocking rotation of the connection terminal (52).