Variable-Cross-Section Electrical Test Probe for Terminal Protection
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Solution Overview
Problem
Probes used for electrical testing often fail to fit optimally into non-standard sized terminals, leading to issues like falling out, expanding the terminal, or damaging the connector housing, particularly in modern vehicles.
Innovation Solution
A probe design with varying cross-sectional areas, including a tip, base, and intermediate portions, allowing secure engagement and increased surface area contact without over-expansion, coupled with a circuit for voltage sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a probe with uniform cross-sectional area is used, then the probe structure is simple, but the probe cannot securely engage with non-standard terminals and may cause damage
Solution Approach 1:
The probe is designed with varying cross-sectional areas at different locations: a first cross-sectional area at the tip portion for inserting into the terminal cavity, a second cross-sectional area at the base portion for structural support, and an intermediate cross-sectional area that transitions between them. This local variation in geometry allows the probe to securely engage with non-standard terminals while maintaining structural integrity, resolving the contradiction between reliability and simplicity.
2Area of moving object
If a probe with larger cross-sectional area is used, then the electrical connection surface area increases, but the probe may over-expand the terminal or damage the connector housing
Solution Approach 1:
The probe employs different cross-sectional areas at different locations to optimize both electrical connection and terminal protection. The tip portion has a first cross-sectional area designed to fit within the terminal cavity without over-expanding it, while the base portion has a larger second cross-sectional area for structural support. This local differentiation allows increased electrical connection surface area without causing terminal expansion or housing damage.
Solution Approach 2:
The probe is segmented into distinct portions (tip portion, intermediate portion, base portion) with different cross-sectional areas. This segmentation allows each portion to serve its specific function: the tip portion makes electrical contact without excessive force, the intermediate portion transitions the cross-sectional area, and the base portion provides structural support. This resolves the contradiction by distributing the area requirements across different segments.
3Adaptability or versatility
If a probe with smaller cross-sectional area is used, then the probe can fit into small terminals, but the electrical connection surface area is reduced and connection reliability decreases
Solution Approach 1:
The probe design implements local quality by varying the cross-sectional area along its length. The tip portion has a smaller first cross-sectional area that can fit into various terminal sizes including non-standard ones, while the base portion has a larger second cross-sectional area that ensures reliable electrical connection and structural stability. This local differentiation allows the probe to adapt to different terminal sizes while maintaining connection reliability.
Solution Approach 2:
The probe is divided into segmented portions with different cross-sectional areas optimized for different functions. The tip portion's smaller cross-section enables adaptability to various terminal sizes, while the base portion's larger cross-section ensures reliable electrical connection. The intermediate portion with its third cross-sectional area provides a smooth transition between these two extremes, resolving the contradiction between adaptability and reliability.
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
Ensures reliable and accurate electrical connection and measurement by minimizing resistance and preventing damage to terminals.
Implementation Method 1
a circuit disposed within the testing body such that the circuit is operatively coupled with the probe such that circuit is configured to sense the voltage level in the electrical terminal cavity
Data Source
AI summary
A device for testing a voltage level in an electrical terminal cavity including a testing body and a probe for contacting the electrical terminal cavity. The probe includes a tip portion having a first cross-sectional area, a base portion having a second cross-sectional area, and an intermediate portion extending from the tip portion to the base portion having a third cross-sectional area. The first cross-sectional area is smaller than the third cross-sectional area, the third cross-sectional area is smaller than the second cross-sectional area, and the intermediate portion is concentric with the tip portion and the base portion. An axis extends between a center of the tip portion, a center of the intermediate portion, a center of the base portion, and a center of the testing body. The device also includes a circuit operatively coupled with the probe to sense the voltage level in the electrical terminal cavity.