Welded Shunt Resistor Connection for Compact Battery State Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery state detection devices are bulky due to the use of bolts and nuts for connecting shunt resistors and battery post terminals, requiring complex assembly and limiting design flexibility and downsizing.
Innovation Solution
The device connects shunt resistors and battery post terminals via welding, eliminating the need for bolts and nuts, allowing for a compact design and simplified assembly, while also improving waterproofing and durability through flat-shaped connections and beveled edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolts and nuts are used to connect the shunt resistor and battery post terminal, then the connection is mechanically secure, but the device size increases and the casing must be enlarged to accommodate the fasteners
Solution Approach 1:
The patent replaces the mechanical fastening system (bolts and nuts) with a welding process to join the shunt resistor and battery post terminal. This substitution eliminates the need for large reception holes and external fasteners, allowing the casing to be significantly downsized while maintaining secure connection. The welding process creates a strong metallurgical bond without requiring the mechanical clearance needed for bolts and nuts.
Solution Approach 2:
The invention extracts and removes the bolts and nuts from the connection system, eliminating the need for the casing to accommodate these external fasteners. By taking out the mechanical fastening elements and replacing them with direct welding, the casing design is freed from the constraints of housing large reception holes, enabling compact dimensions.
2Strength
If bolts and nuts are used for connection, then the assembly is mechanically robust, but the assembly process becomes complex and time-consuming requiring multiple steps
Solution Approach 1:
The patent replaces the multi-step mechanical assembly process (inserting bolts, threading nuts, tightening with tools) with a single welding operation. This substitution dramatically simplifies the assembly process, reducing the number of steps and eliminating the need for manual tool operations, thereby significantly improving productivity while maintaining connection strength through the weld joint.
Solution Approach 2:
The welding process performs the connection action in a single preliminary operation rather than requiring sequential steps of bolt insertion, nut attachment, and tightening. The welding operation completes the entire joining process in one action, eliminating subsequent adjustment and tightening steps required for mechanical fasteners.
3Ease of manufacture
If reception holes are formed for bolts, then the connection is achievable, but the design flexibility of the battery post terminal is reduced and adaptation to various battery types becomes difficult
Solution Approach 1:
By replacing the mechanical fastening system with welding, the invention eliminates the need for precisely positioned reception holes that constrain design flexibility. The welding process can accommodate various terminal geometries and positions without requiring pre-formed holes, enabling easy adaptation to different battery post terminal designs and types.
Solution Approach 2:
The welding-based connection system provides universal adaptability to work with various battery post terminal configurations, shapes, and materials. Unlike bolt connections that require specific hole patterns, the welding process can be applied to diverse terminal designs, making the shunt resistor connection method universally applicable across different battery types and terminal styles.
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
This configuration enables downsizing, reduces manufacturing time, enhances waterproofing, and allows for flexible design changes, enabling adaptation to various battery post structures without altering the shunt resistor or casing designs.
Implementation Method 1
The conductor part and the shunt resistor connecting part are welded to each other
Data Source
AI summary
A battery state detection device (1) includes a shunt resistor (7) and a battery post terminal (4). The shunt resistor (7) includes a second conductor part (12) in the shape of a flat plate. The battery post terminal (4) includes a battery post connecting part (20) for connection to a battery post, and a shunt resistor connecting part (22) for connection to the second conductor part (12) of the shunt resistor (7). The shunt resistor connecting part (22) is in the shape of a flat plate. The second conductor part (12) of the shunt resistor (7) and the shunt resistor connecting part (22) of the battery post terminal (4) are connected to each other by welding.