Wire harness integrated busbar with positioning function and assembling method thereof

By using positioning blocks and positioning columns in the line harness CCS, and forming a limit part through the thermal riveting process, the problems of high fixing costs and unreliable welding of nickel sheets and buses in the prior art are solved, and lower costs and higher production efficiency are achieved.

CN119542687APending Publication Date: 2025-02-28DONGGUAN GUI XIANG INSULATION MATERIAL CO LTD
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Patent Information

Application Number
CN202411741570.6
Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
Filing Date
2024-11-29
Publication Date
2025-02-28

AI Technical Summary

Technical Problem

In the existing wire harness CCS, the fixing cost of nickel sheets and confluents is high, the welding is unreliable, and the processing accuracy requirements are high, which affects production efficiency and manufacturing costs.

Method used

The integrated busbar with positioning function is adopted to position the bus and nickel sheet through the positioning block and the positioning column, and the limiting part is formed through the thermal rivet process to make the two fit and ensure welding quality.

Benefits of technology

The fixed cost of nickel sheets and confluent parts is reduced, the welding quality is improved, the processing accuracy requirements are reduced, and the production efficiency and manufacturing cost control are improved.

✦ Generated by Eureka AI based on patent content.

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Abstract

A wire harness integrated busbar with a positioning function comprises a support and a plurality of battery cell connecting assemblies, each battery cell connecting assembly comprises a bus member and a wire harness, the bus member is fixed on the support, a nickel sheet is arranged at the end of the wire harness, the wire harness integrated busbar further comprises a plurality of positioning blocks, positioning columns are arranged on the positioning blocks, and the positioning columns are fixed on the support. Through holes are formed in the confluence piece and the nickel piece, the confluence piece and the nickel piece are arranged on the positioning column in a sleeving manner, a limiting part is formed at the free end of the positioning column through a hot riveting process, and the limiting part is used for enabling the confluence piece to be attached to the nickel piece. The invention further provides an assembling method using the wire harness integrated busbar. Compared with the prior art, the wiring harness integrated busbar is provided with the positioning blocks, so that no gap is formed between the confluence piece and the nickel sheet, the welding quality of the confluence piece and the nickel sheet is fully ensured, and the problem of insufficient welding caused by the gap between the confluence piece and the nickel sheet is avoided. The positioning block can be suitable for all types of CCS, the universality is high, and the cost is further reduced.
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Description

Technical Field

[0001] The invention belongs to the technical field of wire harness integrated busbars, and in particular relates to a wire harness integrated busbar with a positioning function and an assembling method thereof. Background Art

[0002] In the field of new energy power and energy storage battery technology, in order to monitor battery performance, a CCS (Cell Contact System) is installed on the battery. Compared with FPC-type CCS, wire harness CCS has better advantages in signal transmission stability, cost, maintainability and current capacity. Therefore, even if the integration of wire harness CCS is not as good as that of FPC-type CCS, it can be widely used in practice.

[0003] With the rapid development of the new energy market, the demand for power and energy storage batteries is increasing, which directly drives the stringent requirements on the production efficiency and cost control of batteries and their components.

[0004] In the wire harness CCS, the fixation of the nickel sheet (connected to the end of the wire harness) and the busbar is a key link to ensure battery performance and safety. In the existing production process, the fixation of the nickel sheet and the busbar mainly depends on the positioning jig (the positioning jig includes a jig body and a cover plate, the jig body is provided with a slot, and the cover plate is covered on the slot). The specific operation steps are: place the busbar on the jig body, then clamp the end of the wire harness in the slot of the jig body, and place the nickel sheet on the busbar, then cover the cover plate on the slot, and press the end of the wire harness to fix the nickel sheet to the busbar. After the nickel sheet is fixed, laser welding is performed to achieve the final fixation of the nickel sheet and the busbar.

[0005] Although the above method can fix the nickel sheet, it has the following defects. First, the cost is high: the manufacturing and maintenance costs of the jig are high, and since the shape and structure of the nickel sheet and the bar sheet of each wiring harness CCS are different, each CCS requires a separate jig, which further increases the overall cost; second, welding is unreliable: affected by the busbar, the positioning jig cannot directly position the four corners of the nickel sheet to fix the nickel sheet. Instead, the above-mentioned cover plate is used to press the end of the wiring harness through the cover plate, and the nickel sheet is fixed by fixing the wiring harness. However, after the cover plate presses the end of the wiring harness, the nickel sheet is easy to warp up, and there is a gap between the nickel sheet and the busbar, which easily leads to a cold weld between the nickel sheet and the busbar, or it cannot be fixed by welding.

[0006] In other solutions, the nickel sheet and the busbar are also fixed by buckling, specifically, an opening is made on the busbar, a bending buckle is made on the nickel sheet, and the bent buckle is buckled into the hole, thereby fixing the nickel sheet and the busbar. However, the processing accuracy of the busbar opening and the nickel sheet bending buckle is high, which places strict requirements on processing equipment and technology, and increases the difficulty of processing. Otherwise, the busbar and the nickel sheet will become loose and cannot be fixed. High-precision processing also affects the overall production efficiency, and also makes it difficult to control the production and manufacturing costs. Summary of the invention

[0007] The purpose of the present invention is to overcome the deficiencies in the prior art and provide a wiring harness integrated busbar with a positioning function.

[0008] To achieve the above objectives, the present invention discloses a wiring harness integrated busbar with a positioning function, comprising a bracket and a plurality of battery cell connection assemblies, wherein the battery cell connection assemblies comprise a busbar and a wiring harness, wherein the busbar is fixed on the bracket, and a nickel sheet is provided at the end of the wiring harness.

[0009] It also includes a plurality of positioning blocks, each of which is provided with a positioning column, each of which is provided with a through hole, the busbar and the nickel sheet are sleeved on the positioning column, and a limiting portion is formed at the free end of the positioning column by a hot riveting process, and the limiting portion is used to make the busbar and the nickel sheet fit together.

[0010] Preferably, the positioning block is formed by injection molding.

[0011] Preferably, the outline of the through hole of the nickel sheet does not exceed the outline of the through hole of the busbar.

[0012] Preferably, the outline of the through hole of the nickel sheet is inside the outline of the through hole of the busbar.

[0013] Preferably, a wiring groove is provided in the middle position of the bracket, the wiring harness is arranged in the wiring groove, a row of limiting grooves are provided on both sides of the wiring groove, one limiting groove is used to install a busbar, and a through hole is provided at the bottom of each limiting groove for connecting the busbar with the battery cell.

[0014] Preferably, the bracket is provided with a mounting groove, and the positioning block is arranged in the accommodating groove.

[0015] Preferably, the through hole is located outside a position on the nickel sheet for welding with the busbar.

[0016] The present invention also provides an assembly method using the wiring harness integrated busbar.

[0017] A method for assembling a wiring harness integrated busbar, wherein the wiring harness integrated busbar is any of the above-mentioned wiring harness integrated busbars with a positioning function, and the assembly steps of the wiring harness integrated busbar are:

[0018] Step S1: placing a positioning block on a processing platform, and sleeve the current collector and the nickel sheet on the positioning column of the positioning block in sequence;

[0019] Step S2: using a hot riveting device to rivet the free end of the positioning column to form the limiting portion, the limiting portion pressing the nickel sheet to make the nickel sheet and the busbar fit together;

[0020] Step S3: welding the nickel sheet and the busbar by welding equipment to form a battery cell connection assembly;

[0021] Step S4: Move the cell connection assembly to the bracket, fix the busbar on the bracket, and form a wiring harness integrated busbar.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] The manifold and the nickel sheet are positioned by setting a positioning block and a positioning column of the positioning block. The free end of the positioning column is formed into a limiting portion through a hot riveting process. The limiting portion can make the manifold and the nickel sheet fit together so that there is no gap between them, which fully guarantees the welding quality of the two and avoids the problem of cold welding caused by the gap between the manifold and the nickel sheet.

[0024] The positioning block is used to position the manifold and the nickel sheet and make them fit together. Compared with the use of a jig, this has lower manufacturing costs and does not require maintenance, which reduces costs. At the same time, the positioning block can be applied to all types of CCS (as long as holes are opened on the manifold and the nickel sheet), and is highly universal, which further reduces costs.

[0025] Compared with the traditional block structure, the positioning of the positioning column and the limiting fixation of the limiting part basically have no processing accuracy requirements, high reliability in use, and are conducive to controlling production costs and production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of the three-dimensional structure of the wiring harness integrated busbar with positioning function in Example 1;

[0027] Figure 2 for Figure 1 Schematic diagram of the three-dimensional exploded structure of the wiring harness integrated busbar with positioning function;

[0028] Figure 3 for Figure 1 Schematic diagram of the three-dimensional structure of the positioning block;

[0029] Bracket 1; wiring groove 11; limiting groove 12; through hole 13; mounting groove 14; positioning block 2; positioning column 21; limiting portion 22; busbar 3; wiring harness 4; nickel sheet 41; through hole 5. DETAILED DESCRIPTION

[0030] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] Example 1

[0032] A wiring harness 4 integrated busbar with positioning function, see Figure 1-Figure 3 , including a bracket 1, a plurality of battery cell connection components and a plurality of positioning blocks 2, the battery cell connection components including a busbar 3 and a wiring harness 4, the busbar 3 is fixed on the bracket 1, and a nickel sheet 41 is provided at the end of the wiring harness 4. A positioning column 21 is provided on the positioning block 2, and a through hole 5 is provided on the busbar 3 and the nickel sheet 41, the busbar 3 and the nickel sheet 41 are sleeved on the positioning column 21, and a limiting portion 22 is formed at the free end of the positioning column 21 by a hot riveting process, and the limiting portion 22 is used to make the busbar 3 and the nickel sheet 41 fit together.

[0033] The above-mentioned wiring harness 4 integrated busbar of this embodiment is provided with a positioning block 2, and the positioning column 21 of the positioning block 2 is used to position the busbar 3 and the nickel sheet 41. The free end of the positioning column 21 forms a limiting portion 22 through a hot riveting process. The limiting portion 22 can make the busbar 3 and the nickel sheet 41 fit together, so that there is no gap between the two, which fully guarantees the welding quality of the two, and avoids the problem of cold welding caused by the gap between the busbar 3 and the nickel sheet 41. The positioning block 2 is used to position the busbar 3 and the nickel sheet 41 and make them fit together. Compared with the method of using a fixture, the manufacturing cost is lower and maintenance is not required, which reduces the cost. At the same time, the positioning block 2 can be applied to all types of CCS (as long as holes are opened on the busbar 3 and the nickel sheet 41), and it has high versatility, which further reduces the cost. Compared with the traditional block structure, the positioning of the positioning column 21 and the limiting fixation of the limiting portion 22 basically have no processing accuracy requirements, high reliability in use, and are conducive to controlling production costs and production efficiency.

[0034] In this embodiment, the positioning block 2 is formed by injection molding.

[0035] In this embodiment, the contour of the through hole 5 of the nickel sheet 41 does not exceed the contour of the through hole 5 of the collector 3. In this way, the collector 3 can support the nickel sheet 41 and prevent the contour of the through hole 5 of the nickel sheet 41 from exceeding the contour of the through hole 5 of the collector 3 (that is, part of the nickel sheet 41 is located in the through hole 5 of the collector 3 (hereinafter referred to as the part of the protrusion located in the through hole 5 of the collector 3), so that during the hot riveting process, the limiting portion 22 presses down the protrusion of the nickel sheet 41, causing the nickel sheet 41 to partially tilt up, thereby affecting the welding effect. Preferably, since there is a clearance fit between the collector 3 and the nickel sheet 41 and the positioning column 21, in order to ensure that the nickel sheet 41 does not protrude from the through hole 5 of the collector 3, the contour of the through hole 5 of the nickel sheet 41 is inside the contour of the through hole 5 of the collector 3.

[0036] In this embodiment, a wiring groove 11 is provided in the middle position of the bracket 1, and the wiring harness 4 is arranged in the wiring groove 11, which makes the arrangement of the wiring harness 4 more regular. A row of limiting grooves 12 are provided on both sides of the wiring groove 11. One limiting groove 12 is used to install a busbar 3, which improves the installation stability and reliability of the busbar 3. A through hole 13 is provided at the bottom of each limiting groove 12 for connecting the busbar 3 with the battery cell.

[0037] In this embodiment, a mounting groove 14 is provided on the bracket 1, and the positioning block 2 is arranged in the accommodating groove. Specifically, the shape and size of the mounting groove 14 are adapted to the positioning block 2, and the positioning block 2 is clamped in the mounting groove 14, which can make the positioning block 2 stably clamped in the mounting groove 14 and reduce shaking.

[0038] In this embodiment, the through hole 5 is located on the outside of the position on the nickel sheet 41 for welding with the busbar 3. In this way, after the hot riveting is completed, even if the nickel sheet 41 is slightly warped, under the action of the wiring harness 4, the nickel sheet 41 can still fit tightly with the busbar 3 to ensure the welding effect, avoiding the through hole 5 on the inside of the welding position. The free end of the nickel sheet 41 will be slightly warped after the hot riveting is completed, affecting the welding quality.

[0039] Example 2

[0040] A method for assembling a wiring harness 4 integrated busbar, wherein the wiring harness 4 integrated busbar is the wiring harness 4 integrated busbar with a positioning function of embodiment 1, and the assembly steps of the wiring harness 4 integrated busbar are as follows:

[0041] Step S1: placing the positioning block 2 on the processing platform, and sequentially sleeve the current collector 3 and the nickel sheet 41 on the positioning column 21 of the positioning block 2;

[0042] In order to enable the positioning block 2 to be stably mounted on the processing platform, the processing platform is provided with a mounting groove 14 as mentioned above, and the positioning block 2 can be stuck in the groove.

[0043] Step S2: using a hot riveting device to rivet the free end of the positioning column 21 to form a limiting portion 22, and the limiting portion 22 presses the nickel sheet 41 to make the nickel sheet 41 and the busbar 3 fit together;

[0044] Step S3: welding the nickel sheet 41 and the busbar 3 using welding equipment to form a cell connection assembly;

[0045] Step S4: Carry the cell connection assembly onto the bracket 1 , fix the busbar 3 onto the bracket 1 , and form an integrated busbar of the wiring harness 4 .

[0046] The above assembly steps of the wiring harness 4 integrated busbar do not require precision for the equipment used, which is conducive to controlling the production cost and improving production efficiency. At the same time, by setting the positioning block 2, the positioning column 21 of the positioning block 2 is used to position the busbar 3 and the nickel sheet 41. The free end of the positioning column 21 is formed into a limiting portion 22 through a hot riveting process. The limiting portion 22 can make the busbar 3 and the nickel sheet 41 fit together so that there is no gap between the two, which fully guarantees the welding quality of the two and avoids the problem of cold welding caused by the gap between the busbar 3 and the nickel sheet 41.

[0047] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A wiring harness integrated busbar with positioning function, comprising a bracket and a plurality of battery cell connection components, wherein the battery cell connection components comprise a busbar and a wiring harness, wherein the busbar is fixed on the bracket, and a nickel sheet is provided at the end of the wiring harness, characterized in that: It also includes a plurality of positioning blocks, each of which is provided with a positioning column, each of which is provided with a through hole, the busbar and the nickel sheet are sleeved on the positioning column, and a limiting portion is formed at the free end of the positioning column by a hot riveting process, and the limiting portion is used to make the busbar and the nickel sheet fit together.

2. The wiring harness integrated busbar with positioning function according to claim 1, characterized in that: The positioning block is formed by injection molding.

3. The wiring harness integrated busbar with positioning function according to claim 1, characterized in that: The outline of the through hole of the nickel sheet does not exceed the outline of the through hole of the busbar.

4. The wiring harness integrated busbar with positioning function according to claim 3, characterized in that: The contour of the through hole of the nickel sheet is inside the contour of the through hole of the busbar.

5. The wiring harness integrated busbar with positioning function according to claim 1, characterized in that: A wiring groove is provided in the middle of the bracket, and the wiring harness is arranged in the wiring groove. A row of limiting grooves are provided on both sides of the wiring groove. One limiting groove is used to install a busbar, and a through hole is provided at the bottom of each limiting groove for connecting the busbar with the battery cell.

6. The wiring harness integrated busbar with positioning function according to claim 1, characterized in that: The bracket is provided with a mounting groove, and the positioning block is arranged in the accommodating groove.

7. The wiring harness integrated busbar with positioning function according to claim 1, characterized in that: The through hole is located outside a position on the nickel sheet for welding with the bus bar.

8. A method for assembling a wiring harness integrated busbar, characterized in that: The wiring harness integrated busbar position is the wiring harness integrated busbar with positioning function as claimed in any one of claims 1 to 7, and the assembly steps of the wiring harness integrated busbar are: Step S1: placing a positioning block on a processing platform, and sleeve the current collector and the nickel sheet on the positioning column of the positioning block in sequence; Step S2: using a hot riveting device to rivet the free end of the positioning column to form the limiting portion, the limiting portion pressing the nickel sheet to make the nickel sheet and the busbar fit together; Step S3: welding the nickel sheet and the busbar by welding equipment to form a battery cell connection assembly; Step S4: Move the cell connection assembly to the bracket, fix the busbar on the bracket, and form a wiring harness integrated busbar.