Sensor Pod Battery Clip

thingiverse

This custom clip is designed specifically for the Sensor Pod, a device that can run off batteries for two years while sampling multiple 1-Wire sensors and six independent digital inputs, in addition to six independent analog inputs. The Sensor Pod operates in tandem with a gateway device that provides internet capability via local LAN. The current design has a major flaw: the use of PCB-mounted battery terminals that flex easily, causing the batteries to separate if the sensor is dropped, often damaging the battery terminals simultaneously. Furthermore, as seen from the pictures above, there's considerable separation between the terminals until the batteries are added, at which point the adjacent battery terminals have less than 2 mm of space. I aimed to create a simple clip that would keep the batteries in place if the unit is dropped and maintain an air gap between the two batteries to prevent shorting. This custom battery clip was designed to meet three key requirements: 1. Provide a friction lock around the batteries to prevent movement. 2. Offer a divider to prevent shorting of the battery terminals. 3. During prototype review, a third requirement was added: provide a mechanism for easy removal of the clip when changing batteries. After thorough review and refinement, I believe the final design has achieved great results: The unit provides just enough clearance that it is locked in place by the outer edges of the Battery terminal clips at the end of each battery, with a simple spacer providing separation of the terminals at either end of the clip. The lip around the top edge allows for easy grip and removal without squeezing the sides. Since this design is specific to my sensor pod, I've included the design files for customization to accommodate similar scenarios in other devices.