Wire Connection Verification Using Differential Voltage Measurement
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Solution Overview
Problem
Existing methods for checking wire connections between test units and batteries are complex and prone to errors, requiring additional equipment and increased testing time, especially as the number of batteries increases.
Innovation Solution
A method involving a tester with a first power channel and a first measuring channel that provides currents and measures voltages to determine if the channels are connected to the same battery, using voltage differences to differentiate between correct and incorrect connections, thereby reducing the need for manual inspection and additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If polarity detection is used to confirm positive/negative terminal connections, then connection polarity can be verified, but it cannot detect whether power channel and measuring channel are connected to the same battery
Solution Approach 1:
The patent introduces a third measuring channel as an intermediary to detect the connection relationship between the power channel and measuring channel. This third channel measures voltages that serve as indicators to determine whether the power and measuring channels are connected to the same battery, resolving the limitation of traditional polarity detection without requiring complex additional equipment
Solution Approach 2:
The system uses voltage measurements from the third measuring channel to provide feedback about the connection status. By comparing voltage differences measured under different current conditions, the system can determine whether channels are correctly connected to the same battery, enabling automatic detection and correction of connection errors
2Measurement precision
If manual operation or additional detection is used to detect power channel and measuring channel connections, then connection accuracy can be improved, but testing time and costs increase
Solution Approach 1:
The patent merges the connection detection function with the existing battery testing process. The third measuring channel is integrated into the test unit, and connection detection is performed automatically during the testing process by measuring voltages while currents are being provided, eliminating the need for separate manual inspection steps
Solution Approach 2:
The system performs self-diagnosis of connection status using its own measuring channels. By having the test unit automatically measure voltages through the third measuring channel and compare them to determine connection correctness, the system eliminates the need for external manual detection, reducing both time and operational complexity
3Difficulty of detecting and measuring
If additional equipment is used for wire connection checking, then detection capability is improved, but costs increase
Solution Approach 1:
The third measuring channel serves multiple functions: it measures battery voltages for normal testing operations and simultaneously serves as a detection tool for verifying wire connections. This multi-functionality allows the system to perform connection detection without requiring separate dedicated detection equipment, reducing overall equipment quantity while maintaining detection capability
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 method reduces testing time and costs by accurately determining correct wire connections through voltage measurements, avoiding noise voltages and providing a correct connection indication based on voltage differences.
Implementation Method 1
providing a first current by a first power channel and measuring a first voltage by a first measuring channel
Implementation Method 2
providing a second current by the first power channel and measuring a second voltage by the first measuring channel
Implementation Method 3
determining whether the first measuring channel and the first power channel are connected to a same battery of the batteries
Data Source
AI summary
A method for checking a wire connection comprises providing a first current by a first power channel and measuring a first voltage by a first measuring channel when each of a positive terminal of the first measuring channel and a positive terminal of the first power channel is connected to one of positive terminals of batteries and each of a negative terminal of the first measuring channel and a negative terminal of the second measuring channel is connected to one of negative terminals of the batteries after measuring the first voltage, providing a second current by the first power channel and measuring a second voltage by the first measuring channel, and determining whether the first measuring channel and the first power channel are connected to a same battery of the batteries.