Bus with finger-proof terminal connector

Abstract

A bus bar assembly for interconnecting components within a multi-module electrical system for a vehicle includes a bus bar having a first distal end and a second distal end; and a first anti-finger terminal connector located on the first distal end of the bus bar and adapted to electrically connect the bus bar to an external terminal wherein the anti-finger terminal connector is adapted to allow limited movement of the first distal end of the bus bar relative to the first anti-finger terminal connector in an x-y plane.

Description

Technical Field

[0001] The present invention generally relates to electrochemical energy storage devices, such as lithium-ion batteries, and more specifically to busbars suitable for facilitating inter-module bolted connections between electrochemical components. Background Technology

[0002] The bolt-connected electrical terminals are designed with a thin, finger-proof feature to prevent accidental contact between the live terminal surface and the operator or tools. These finger-proof electrical terminals enable safe and simplified battery pack assembly and improve voltage scalability in multi-module battery packs. However, the assembly of electric vehicles and their corresponding battery modules is typically automated, requiring precise placement of the modules to be connected.

[0003] Therefore, while current terminal connectors achieve their intended purpose, there is a need for a new type of improved busbar with a finger-resistant terminal connector to allow the distal end of the busbar to slide relative to the finger-resistant terminal connector in the xy plane, thereby enabling the automated assembly of modular battery systems where the placement and dimensional tolerances of components are not very precise. Summary of the Invention

[0004] According to several aspects, a bus assembly for interconnecting components within a multi-module electrical system for a vehicle, according to an exemplary embodiment of the present disclosure, includes: a bus having a first distal end and a second distal end; and a first finger-resistant terminal connector located on the first distal end of the bus and adapted to electrically connect the bus to an external terminal, wherein the finger-resistant terminal connector is adapted to allow limited movement of the first distal end of the bus relative to the first finger-resistant terminal connector in the xy plane.

[0005] According to another aspect, the busbar includes: a first groove formed therein and longitudinally positioned along the central axis of the busbar, the first groove being adjacent to a first distal end of the busbar; a second groove formed therein and longitudinally positioned along the central axis of the busbar, the second groove being adjacent to the first groove; and a protective outer coating extending along the length of the busbar, the first distal end of the busbar including the first groove and the second groove extending beyond the protective outer coating, wherein the finger-resistant terminal connector package includes the first distal end of the busbar including the first groove and the second groove, and extends on a first edge of the protective outer coating.

[0006] According to another aspect, the first finger-proof terminal connector includes an upper terminal cap and a lower terminal cap, the upper and lower terminal caps including features adapted to secure the upper cap to the lower cap, wherein a first distal end of a busbar is encapsulated therebetween, the upper terminal cap of the first finger-proof terminal connector including a fastener retaining cap having features adapted to rotatably secure a terminal fastener therein, wherein the terminal fastener extends through a first groove within the busbar, an alignment post extends through a second groove within the busbar and engages with a limiting stop groove formed in the lower terminal cap, the lower terminal cap of the first finger-proof terminal connector including a terminal tube supported in an alignment recess formed therein, the terminal tube being adapted to engage an external terminal and including a contact surface that contacts the busbar and is adapted to establish an electrical connection therebetween, wherein the terminal fastener extends through the contact surface of the terminal tube and is adapted to engage the external terminal and secure the first distal end of the busbar and the first finger-proof terminal connector to the external terminal, and establish an electrical connection between the busbar and the external terminal through the terminal tube.

[0007] According to another aspect, the width and length of the first slot are both greater than the diameter of the terminal fastener extending through it, and the width and length of the second slot are both greater than the diameter of the alignment post extending through it, wherein the first distal end of the busbar is movable in the xy plane relative to the first anti-finger terminal connector before the terminal fastener is fixed to the external terminal.

[0008] According to another aspect, the upper terminal cap of the first finger-protection terminal connector includes a pick-up and place feature adapted to allow the bus assembly to be gripped by an automated tool, wherein the bus can move relative to the first finger-protection terminal connector in the xy plane when the bus assembly is supported by the automated tool gripping the pick-up and place feature of the upper terminal cap of the first finger-protection terminal connector.

[0009] According to another aspect, the outer protective cover of the busbar includes a pick-up and placement feature adapted to allow the busbar assembly to be gripped by an automated tool, wherein when the busbar assembly is supported by the automated tool of the pick-up and placement feature of the protective outer coating of the busbar, the first finger-proof terminal connector is movable relative to the busbar in the xy plane.

[0010] According to another aspect, the bus assembly also includes a second finger-proof terminal connector located on a second distal end of the bus and adapted to electrically connect the bus to an external terminal, wherein the second finger-proof terminal connector is adapted to allow limited movement of the second distal end of the bus relative to the second finger-proof terminal connector in the xy plane.

[0011] According to another aspect, the busbar further includes: a third groove formed therein and longitudinally positioned along the central axis of the busbar, the third groove being adjacent to a second distal end of the busbar; and a fourth groove formed therein and longitudinally positioned along the central axis of the busbar, the fourth groove being adjacent to the third groove of the busbar, wherein a protective outer coating extends along the length of the busbar, the second distal end of the busbar including the third and fourth grooves extending beyond the protective outer coating, wherein the second finger-resistant terminal connector package includes the second distal end of the busbar including the third and fourth grooves and extends on a second edge of the protective outer coating.

[0012] According to another aspect, the second finger-proof terminal connector includes an upper terminal cap and a lower terminal cap, the upper and lower terminal caps including features adapted to secure the upper cap to the lower cap, wherein a second distal end of the busbar is encapsulated therebetween. The upper terminal cap of the second finger-proof terminal connector includes a fastener retaining cap having features adapted to rotatably secure a terminal fastener therein, wherein the terminal fastener extends through a third groove within the busbar, and an alignment post extends through a fourth groove within the busbar and engages a limiting stop groove formed within the lower terminal cap of the second finger-proof terminal connector. The lower terminal cap of the second finger-proof terminal connector includes a terminal cylinder supported within an alignment recess formed therein, the terminal cylinder being adapted to engage an external terminal and including a contact surface that contacts the busbar and is adapted to establish an electrical connection therebetween, wherein the terminal fastener extends through the contact surface of the terminal cylinder and is adapted to engage the external terminal and secure the second distal end of the busbar and the second finger-proof terminal connector to the external terminal, and an electrical connection is formed between the busbar and the external terminal through the terminal cylinder.

[0013] According to another aspect, the width and length of the third slot are both greater than the diameter of the terminal fastener extending through it, and the width and length of the fourth slot are both greater than the diameter of the alignment post extending through it. Before the terminal fastener is fixed to the external terminal, the second distal end of the busbar can move in the xy plane relative to the second anti-finger terminal connector.

[0014] According to another aspect, the upper terminal cap of the second finger-protection terminal connector includes a pick-up and placement feature adapted to allow the bus assembly to be gripped by an automated tool, wherein when the bus assembly is supported by the automated tool gripping the pick-up and placement feature of the upper terminal cap of the second finger-protection terminal connector, the bus can move relative to the second finger-protection terminal connector in the xy plane, and when the bus assembly is supported by the automated tool gripping the protective outer coating of the bus, each of the first and second finger-protection terminal connectors can move independently relative to the bus in the xy plane.

[0015] According to another aspect, the fastener retaining cap of each of the first and second finger-resistant terminal connectors includes an external thread adapted to engage an internal thread of a pyrophoric cap, the pyrophoric cap being adapted to removably cover an opening within the fastener retaining cap, the opening within the fastener retaining cap being adapted to allow access to the terminal fastener.

[0016] According to several aspects, a busbar assembly for interconnecting components within a multi-module electrical system for a vehicle, according to exemplary embodiments of the present disclosure, includes: a busbar having a first distal end and a second distal end; a first finger-resistant terminal connector located on the first distal end of the busbar and adapted to electrically connect the busbar to an external terminal, wherein the finger-resistant terminal connector is adapted to allow limited movement of the first distal end of the busbar relative to the first finger-resistant terminal connector in an xy plane; and a second finger-resistant terminal connector located on the second distal end of the busbar and adapted to electrically connect the busbar to an external terminal, wherein the second finger-resistant terminal connector is adapted to allow limited movement of the second distal end of the busbar relative to the second finger-resistant terminal connector in an xy plane.

[0017] According to another aspect, the busbar includes: a first groove formed therein and longitudinally positioned along the central axis of the busbar, the first groove being adjacent to a first distal end of the busbar; a second groove formed therein and longitudinally positioned along the central axis of the busbar, the second groove being adjacent to the first groove; a third groove formed therein and longitudinally positioned along the central axis of the busbar, the third groove being adjacent to a second distal end of the busbar; a fourth groove formed therein and longitudinally positioned along the central axis of the busbar, the fourth groove being adjacent to the third groove; and a protective outer coating extending along the length of the busbar, the first distal end of the busbar including the first groove and the second groove extending beyond the protective outer coating, wherein a first finger-resistant terminal connector package includes the first distal end of the busbar including the first groove and the second groove and extends on a first edge of the protective outer coating, and the second distal end of the busbar including the third groove and the fourth groove extends beyond the protective outer coating, wherein a second finger-resistant terminal connector package includes the second distal end of the busbar including the third groove and the fourth groove and extends on a second edge of the protective outer coating.

[0018] According to another aspect, the first finger-protection terminal connector and the second finger-protection terminal connector are substantially the same. Each of the first and second finger-protection terminal connectors includes an upper terminal cap and a lower terminal cap, the upper and lower terminal caps including features adapted to secure the upper cap to the lower cap, wherein the distal end of the busbar is encapsulated therebetween. The upper terminal cap of each of the first and second finger-protection terminal connectors includes a fastener retaining cap having features adapted to rotatably secure a terminal fastener therein. The terminal fastener of the first finger-protection terminal connector extends through a first groove within the busbar, and the terminal fastener of the second finger-protection terminal connector extends through a third groove within the busbar. Alignment posts are also included; the alignment post of the first finger-protection terminal connector extends through a second groove within the busbar and engages with a limiting stop groove formed in the lower terminal cap of the first finger-protection terminal connector, and the alignment post of the second finger-protection terminal connector extends through a fourth groove within the busbar and engages with a limiting stop groove formed in the lower terminal cap of the first finger-protection terminal connector. A limiting stop groove is formed in the lower terminal cap of the second finger-proof terminal connector. The lower terminal cap of each of the first and second finger-proof terminal connectors includes a terminal tube supported in an alignment recess formed therein. The terminal tube of each of the first and second finger-proof terminal connectors is adapted to engage an external terminal and includes a contact surface that contacts a busbar and is adapted to establish an electrical connection therebetween. The terminal fastener of the first finger-proof terminal connector extends through the contact surface of the terminal tube and is adapted to engage an external terminal and secure a first distal end of the busbar and the first finger-proof terminal connector to the external terminal, and establishes an electrical connection between the first distal end of the busbar and the external terminal through the terminal tube. The terminal fastener of the second finger-proof terminal connector extends through the contact surface of the terminal tube and is adapted to engage an external terminal and secure a second distal end of the busbar and the second finger-proof terminal connector to the external terminal, and establishes an electrical connection between the second distal end of the busbar and the external terminal through the terminal tube.

[0019] According to another aspect, the width and length of the first slot are both greater than the diameter of the terminal fastener of the first anti-finger terminal connector extending through it, and the width and length of the second slot are both greater than the diameter of the alignment post of the first anti-finger terminal connector extending through it, wherein the first distal end of the busbar is movable in the xy plane relative to the first anti-finger terminal connector before the terminal fastener of the first anti-finger terminal connector is fixed to the external terminal, and the width and length of the third slot are both greater than the diameter of the terminal fastener of the second anti-finger terminal connector extending through it, and the width and length of the fourth slot are both greater than the diameter of the alignment post of the second anti-finger terminal connector extending through it, wherein the second distal end of the busbar is movable in the xy plane relative to the second anti-finger terminal connector before the terminal fastener of the second anti-finger terminal connector is fixed to the external terminal.

[0020] According to another aspect, the upper terminal cap of the first finger-resistant terminal connector includes a pick-and-place feature adapted to allow gripping of the bus assembly by an automated tool, wherein the bus is movable in the xy plane relative to the first finger-resistant terminal connector when supported by the automated tool gripping the pick-and-place feature of the upper terminal cap of the first finger-resistant terminal connector; the upper terminal cap of the second finger-resistant terminal connector includes a pick-and-place feature adapted to allow gripping of the bus assembly by an automated tool, wherein the bus is movable in the xy plane relative to the second finger-resistant terminal connector when supported by the automated tool gripping the pick-and-place feature of the upper terminal cap of the second finger-resistant terminal connector; and the outer protective cover of the bus includes a pick-and-place feature adapted to allow gripping of the bus assembly by an automated tool, wherein each of the first and second finger-resistant terminal connectors is movable independently in the plane relative to the bus when supported by the automated tool gripping the pick-and-place feature of the outer protective coating of the bus.

[0021] According to another aspect, the fastener retaining cap of each of the first and second anti-finger terminal connectors includes an external thread adapted to engage the internal thread of the self-ignition cap, the self-ignition cap of the first anti-finger terminal connector being adapted to removably cover an opening within the fastener retaining cap of the first anti-finger terminal connector, the opening being adapted to allow access to the terminal fastener of the first anti-finger terminal connector, and the self-ignition cap of the second anti-finger terminal connector being adapted to removably cover an opening within the fastener retaining cap of the second anti-finger terminal connector, the opening being adapted to allow access to the terminal fastener of the second anti-finger terminal connector.

[0022] Further areas of application will become apparent from the description provided herein. It should be understood that these descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0023] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0024] Figure 1 This is a schematic diagram of a vehicle having an electrical system including a busbar assembly, according to exemplary embodiments of the present disclosure;

[0025] Figure 2 This is a perspective view of a busbar assembly according to an exemplary embodiment of the present disclosure;

[0026] Figure 3 yes Figure 1 The diagram shows a perspective view of the bus assembly, wherein the first finger-proof terminal connector of the bus assembly is attached to the external terminal of the battery module;

[0027] Figure 4 This is a cross-sectional view showing either the same first anti-finger terminal connector or the second anti-finger terminal connector according to an exemplary embodiment;

[0028] Figure 5 yes Figure 4 Exploded view;

[0029] Figure 6 It is a top view showing either the same first or second distal end of the busbar of the busbar assembly;

[0030] Figure 7A This is a side sectional view of the first and second finger-protection terminal connectors, wherein the terminal fasteners are not screwed into the external terminals; and

[0031] Figure 7B This is a side sectional view of the first and second anti-finger terminal connectors, wherein terminal fasteners are screwed into the external terminals.

[0032] The accompanying drawings are not necessarily drawn to scale, and some features may be enlarged or minimized, for example, to show details of specific components. In some cases, well-known components, systems, materials, or methods are not described in detail to avoid obscuring this disclosure. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but only as the basis for the claims and as a representative basis for teaching those skilled in the art to apply this disclosure in various ways. Detailed Implementation

[0033] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses. Furthermore, it is not intended to be bound by any express or implied theory presented in the foregoing technical fields, background art, summary of the invention, or the following detailed description. It should be understood that in all the drawings, corresponding reference numerals denote similar or corresponding parts and features. As used herein, the term "module" means any hardware, software, firmware, electronic control components, processing logic, and / or processor device, individually or in any combination, including but not limited to: application-specific integrated circuits (ASICs), electronic circuits, processors (shared, dedicated, or grouped), and memory executing one or more software or firmware programs, combinational logic circuits, and / or other suitable components providing the described functionality. Although the drawings shown herein depict examples with certain element arrangements, additional intermediate elements, devices, features, or components may be present in actual embodiments. It should also be understood that the drawings are merely illustrative and may not be drawn to scale.

[0034] As used herein, the term "vehicle" is not limited to automobiles. While this article primarily describes the technology in the context of automobiles, the technology is not limited to automobiles. These concepts can be applied to a variety of applications, such as aircraft, ships, other vehicles, and consumer electronics components.

[0035] Exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those skilled in the art. Numerous specific details, such as examples of specific components, parts, apparatuses, and methods, are set forth to provide a full understanding of embodiments of the disclosure. It will be apparent to those skilled in the art that specific details are not required, exemplary embodiments may be presented in many different forms, and none should be construed as limiting the scope of the disclosure. In some exemplary embodiments, well-known processes, well-known apparatus structures, and well-known technologies are not described in detail.

[0036] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” may also be intended to include the plural forms. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and thus specify the presence of stated features, elements, components, steps, integrals, operations, and / or parts, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, parts, and / or groups thereof. Although the open-ended term “comprising” should be understood as a non-limiting term used to describe and claim the various embodiments presented herein, in some respects it may be understood alternatively as a more restrictive and binding term, such as “consisting of” or “substantially consisting of.” Therefore, for any given embodiment describing composition, materials, components, elements, features, integrals, operation, and / or process steps, this disclosure also specifically includes embodiments consisting of or substantially consisting of such described composition, materials, components, elements, features, integrals, operation, and / or process steps. In the case of "consisting of," alternative embodiments exclude any additional composition, materials, components, elements, features, integrals, operation, and / or process steps, while in the case of "substantially consisting of," any additional composition, materials, components, elements, features, integrals, operation, and / or process steps that substantially affect the essential characteristics and novelty are excluded from such embodiments, but any composition, materials, components, elements, features, integrals, operation, and / or process steps that do not substantially affect the essential characteristics and novelty can be included in the embodiments.

[0037] Unless the specific order of execution is explicitly stated, no method steps, processes, and operations described herein should be construed as requiring them to be performed in the particular order discussed or shown. It should also be understood that additional or alternative steps may be employed unless otherwise stated.

[0038] When a component, element, or layer is referred to as being "on," "joined to," "connected to," or "coupled to" another component, element, or layer, it may be directly on, joined to, connected to, or coupled to the other component, element, or layer, or there may be intermediate components, elements, or layers. Conversely, when an element is referred to as being "directly on," "directly joined to," "directly connected to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the related listed items.

[0039] Although terms such as “first,” “second,” and “third” may be used herein to describe various steps, elements, components, regions, layers, and / or portions, these steps, elements, components, regions, layers, and / or portions should not be limited by these terms unless otherwise stated. These terms may be used only to distinguish one step, element, component, region, layer, or portion from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms, when used herein, do not imply order or sequence. Therefore, without departing from the teachings of exemplary embodiments, the first step, element, component, region, layer, or portion discussed below may be referred to as the second step, element, component, region, layer, or portion.

[0040] For ease of description, spatial or temporal relative terms such as “front,” “back,” “inner,” “outer,” “below,” “below,” “down,” “above,” “up,” etc., may be used herein to describe the relationship between one element or feature and another element or feature as shown in the accompanying drawings. In addition to the orientations shown in the accompanying drawings, spatial or temporal relative terms may be intended to cover different orientations of the apparatus or system during use or operation.

[0041] Throughout this disclosure, numerical values ​​represent approximate measurements or limitations of a range to cover slight deviations from a given value and embodiments having approximately the mentioned value as well as embodiments having exactly the mentioned value. Except for the working examples provided at the end of the detailed embodiments, all numerical values ​​of parameters (e.g., quantities or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term “about,” regardless of whether “about” actually precedes the numerical value. “About” indicates that the referred numerical value allows for some slight inaccuracy (accuracy by some method to approximate the value; approximate or reasonably approximate the value; almost). If the inaccuracy provided by “about” is not otherwise understood in this common sense in the art, then “about” as used herein at least indicates a deviation that can be produced by common methods of measuring and using such a parameter. For example, “about” with respect to percentages includes a deviation of + / -5%, “about” with respect to temperature includes a deviation of + / -5 degrees, and “about” with respect to distance includes a deviation of + / -10%. In addition, the disclosure of the range includes the disclosure of all values ​​within the entire range and the disclosure of further subdivisions of the range, including the disclosure of endpoints and subranges given for that range.

[0042] In addition, the disclosure of the range includes the disclosure of all values ​​within the entire range and the disclosure of further subdivisions of the range, including the disclosure of endpoints and subranges given for that range.

[0043] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. According to the exemplary embodiments, Figure 1 A vehicle 10 is shown having a busbar assembly 50 for interconnecting components within a multi-module electrical system 38. The vehicle 10 generally includes a chassis 12, a body 14, front wheels 16, and rear wheels 18. The body 14 is arranged on the chassis 12 and substantially surrounds the components of the vehicle 10. The body 14 and chassis 12 can collectively form a frame. The front wheels 16 and rear wheels 18 are each rotatably connected to the chassis 12 near a respective corner of the body 14.

[0044] In various embodiments, vehicle 10 is an autonomous vehicle. For example, autonomous vehicle 10 is a vehicle 10 that is automatically controlled to transport passengers from one location to another. Vehicle 10 is depicted as a passenger car in the illustrated embodiment, but it should be understood that any other vehicle may be used, including motorcycles, vans, sport utility vehicles (SUVs), recreational vehicles (RVs), etc. In exemplary embodiments, vehicle 10 is equipped with a so-called Level 4 or Level 5 automation system. Level 4 system means "high automation," referring to the autonomous driving system performing all aspects of a dynamic driving task in a specific driving mode even if a human driver does not properly respond to an intervention request. Level 5 system means "full automation," referring to the autonomous driving system performing all aspects of a dynamic driving task at all times under all road and environmental conditions that a human driver can manage. The novel aspects of this disclosure also apply to non-autonomous vehicles.

[0045] As shown in the figure, vehicle 10 generally includes a propulsion system 20, a drivetrain 22, a steering system 24, a braking system 26, a sensor system 28, an actuator system 30, at least one data storage device 32, a vehicle controller 34, and a wireless communication module 36. In embodiments where vehicle 10 is an electric vehicle, the drivetrain 22 may be absent. In various embodiments, the propulsion system 20 may include an internal combustion engine, an electric motor (such as a traction motor), and / or a fuel cell propulsion system. Vehicle 10 includes an electrical system 38. In hybrid or all-electric vehicles, the engine components, fuel supply system, and exhaust system of an internal combustion engine (ICE) vehicle are replaced by one or more electric motors, a battery pack, and battery cooling and charging hardware of the electrical system 38. Many hybrid electric and all-electric vehicles employ rechargeable battery packs to store and supply the power required to operate the motors of the electric propulsion system 20. To generate sufficient traction power for vehicle range and speed, battery packs are significantly larger, more powerful, and have a higher capacity (ampere-hours) than standard 12-volt starter, lighting, and ignition (SLI) batteries. Compared to the individual cells of SLI batteries, modern electric vehicle battery packs stack battery cells into individual battery modules, which are then mounted to the vehicle chassis 12, for example, via a battery pack housing or support tray. Modules consisting of stacked electrochemical battery cells can be connected in series or parallel using an electrical interconnect board (ICB), or the modules can be directly connected to each other. The individual battery modules are electrically connected together via a bus assembly 50, which is adapted to connect one battery module to another or to the ICB.

[0046] The drivetrain 22 is configured to transmit electrical power from the propulsion system 20 to the front wheels 16 and rear wheels 18 of the vehicle according to a selectable speed ratio. According to various embodiments, the drivetrain 22 may include a stepped automatic transmission, a continuously variable transmission (CVT), or other suitable transmission. The braking system 26 is configured to provide braking torque to the front wheels 16 and rear wheels 18 of the vehicle. In various embodiments, the braking system 26 may include friction brakes, brake-by-wire, regenerative braking systems (e.g., electric motors), and / or other suitable braking systems. The steering system 24 affects the position of the front wheels 16 and rear wheels 18. Although depicted as including a steering wheel for illustrative purposes, in some embodiments contemplated within the scope of this disclosure, such as for fully automated vehicles, the steering system 24 may not include a steering wheel.

[0047] Sensor system 28 includes one or more sensing devices 40a-40n for sensing observable conditions of the external and / or internal environment of the autonomous vehicle 10. Sensing devices 40a-40n may include, but are not limited to, radar, lidar, global positioning system, optical cameras, thermal imagers, ultrasonic sensors, and / or other sensors. Cameras may include two or more digital cameras spaced apart from each other at a selected distance, wherein the two or more digital cameras are used to acquire stereo images of the surrounding environment to obtain a three-dimensional image or map. Multiple sensing devices 40a-40n are used to determine information about the environment surrounding the vehicle 10. In an exemplary embodiment, multiple sensing devices 40a-40n include a motor speed sensor, a motor torque sensor, an electric drive motor voltage and / or current sensor, an accelerator pedal position sensor, a coolant temperature sensor, a cooling fan speed sensor, and a transmission oil temperature sensor.

[0048] In another exemplary embodiment, the plurality of sensing devices 40a-40n further include sensors for determining information about the environment surrounding the vehicle 10, such as an ambient air temperature sensor, an atmospheric pressure sensor, and / or a camera and / or video camera positioned to observe the environment in front of the vehicle 10. In another exemplary embodiment, at least one of the plurality of sensing devices 40a-40n can measure distances in the environment surrounding the vehicle 10.

[0049] The actuator system 30 includes one or more actuator devices 42a-42n that control one or more features of the vehicle 10, such as, but not limited to, the propulsion system 20, the transmission system 22, the steering system 24, and the braking system 26.

[0050] The vehicle controller 34 includes at least one processor 44 and a computer-readable storage device or medium 46. The at least one data processor 44 can be any custom or commercially available processor, central processing unit (CPU), graphics processing unit (GPU), auxiliary processor among a plurality of processors associated with the vehicle controller 34, semiconductor-based microprocessor (in the form of a microchip or chipset), macroprocessor, any combination thereof, or any device typically used to execute instructions. The computer-readable storage device or medium 46 can include, for example, volatile and non-volatile memory such as read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is persistent or non-volatile memory that can be used to store various operational variables when at least one data processor 44 is powered off. The computer-readable storage device or medium 46 may be implemented using any of a variety of known memory devices such as PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory (flash memory), or any other electrical, magnetic, optical, or combined memory device capable of storing data, some of which represents executable instructions used by the controller 34 when controlling the vehicle 10.

[0051] The instructions may include one or more separate programs, each of which includes an ordered list of executable instructions for implementing logical functions. When executed by at least one processor 44, the instructions receive and process signals from the sensor system 28, execute logic, calculations, methods, and / or algorithms for automatically controlling components of the vehicle 10, and generate control signals to the actuator system 30 based on the logic, calculations, methods, and / or algorithms to automatically control components of the vehicle 10. Although Figure 1 Only one controller 34 is shown, but embodiments of vehicle 10 may include any number of controllers 34 that communicate via any suitable communication medium or combination of communication media and cooperate in processing sensor signals, executing logic, calculations, methods and / or algorithms, and generating control signals to automatically control the features of autonomous vehicle 10.

[0052] The wireless communication module 36 is configured to wirelessly transmit and receive information from other remote entities 48, such as, but not limited to, other vehicles (“V2V” communication), infrastructure (“V2I” communication), remote systems, remote servers, cloud computers, and / or personal devices. In an exemplary embodiment, the communication system 36 is a wireless communication system configured to communicate via a wireless local area network (WLAN) using the IEEE 802.11 standard or by using cellular data communication. However, additional or alternative communication methods, such as Dedicated Short Range Communication (DSRC) channels, are also considered to be within the scope of this disclosure. A DSRC channel refers to a one-way or two-way short- to medium-range wireless communication channel designed specifically for motor vehicle applications, along with a corresponding set of protocols and standards.

[0053] The vehicle controller 34 is a non-general-purpose electronic control device that includes a pre-programmed digital computer or processor, memory or non-transitory computer-readable medium, and transceivers (or input / output ports) for storing data such as control logic, software applications, instructions, computer code, data, lookup tables, etc. Computer-readable medium includes any type of media that can be accessed by a computer, such as read-only memory (ROM), random access memory (RAM), hard disk drive, optical disc (CD), digital video disc (DVD), or any other type of memory. "Non-transitory" computer-readable medium does not include wired, wireless, optical, or other communication links that transmit transient electrical or other signals. Non-transitory computer-readable medium includes media that can permanently store data and media that can store data and subsequently be rewritten, such as rewritable optical discs or erasable memory devices. Computer code includes any type of program code, including source code, object code, and executable code.

[0054] Reference Figure 2 and Figure 3 According to an exemplary embodiment of the present disclosure, the bus assembly 50 includes a bus 52 having a first distal end 54A and a second distal end 54B. For example... Figure 2As shown, the bus assembly 50 includes a first finger-resistant terminal connector 56A located at a first distal end 54A of the bus 52 and a second finger-resistant terminal connector 56B located at a second distal end 54B of the bus 52. Each of the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B is adapted to electrically connect the bus 52 to an external terminal 58. The external terminal 58 can be a terminal for any module or electronic module within a battery pack designed with appropriate terminals, and by way of non-limiting example, can be a terminal for a battery module 60 or an electrical interconnect board (ICB), BDU, intermediate group, or fuse box. Therefore, the bus assembly 50 can be used to interconnect two battery modules in series or to connect a battery module to an ICB. Figure 3 As shown, the first finger-protection terminal connector 56A and the first distal end 54A of the bus 52 are fixed to the external terminal 58 of the battery module 60. In other embodiments, the bus assembly 50 includes only the first finger-protection terminal connector 56A located on the first distal end 54A of the bus, and the second distal end 54B of the bus 52 includes different connection features for connecting the bus assembly 50 to electrical components within the electrical system 38. It should be understood that the first finger-protection terminal connector 56A and the second finger-protection terminal connector 56B are the same finger-protection terminal connectors 56A and 56B, the only difference being that the first finger-protection terminal connector 56A is located on the first distal end 54A of the bus 52, and the second finger-protection terminal connector 56B is located on the second distal end 54B of the bus 52.

[0055] In an exemplary embodiment, when the first finger-proof terminal connector 56A is not connected to the external terminal 58, the first finger-proof terminal connector 56A is adapted to allow limited movement of the first distal end 54A of the bus 52 relative to the first finger-proof terminal connector 56A in the xy plane defined by the x-axis 62 and the y-axis 64, and when the second finger-proof terminal connector 56B is not connected to the external terminal 58, the second finger-proof terminal connector 56B is adapted to allow limited movement of the second distal end 54B of the bus 52 relative to the second finger-proof terminal connector 56B in the xy plane defined by the x-axis 62 and the y-axis 64.

[0056] Reference Figure 6 ,in Figure 6Representing the same first distal end 54A and second distal end 54B of busbar 52, busbar 52 includes: a first slot 66A formed therein and longitudinally positioned along the central axis 68 of busbar 52, the first slot 66A being adjacent to the first distal end 54A of busbar 52; and a second slot 70A formed therein and longitudinally positioned along the central axis 68 of busbar 52, the second slot 70A being adjacent to the first slot 66A but further away from the first distal end 54A of busbar 52 than the first slot 66A. Similarly, busbar 52 includes: a third slot 66B formed therein and longitudinally positioned along the central axis 68 of busbar 52, the third slot 66B being adjacent to the second distal end 54B of busbar 52; and a fourth slot 70B formed therein and longitudinally positioned along the central axis 68 of busbar 52, the fourth slot 70B being adjacent to the third slot 66B but further away from the second distal end 54B of busbar 52 than the third slot 66B.

[0057] The protective outer coating 72 extends along the length of the busbar 52. A first distal end 54A of the busbar 52, including the first slot 66A and the second slot 70A, extends beyond the protective outer coating 72, wherein the first finger-resistant terminal connector 56A encapsulates the first distal end 54A of the busbar 52 including the first slot 66A and the second slot 70A, and extends on the first edge 74 of the protective outer coating 72. A second distal end 54B of the busbar 52, including the third slot 66B and the fourth slot 70B, extends beyond the protective outer coating 72, wherein the second finger-resistant terminal connector 56B encapsulates the second distal end 54B of the busbar 52 including the third slot 66B and the fourth slot 70B, and extends on the second edge 76 of the protective outer coating 72.

[0058] Reference Figure 4 and Figure 5 ,in Figure 4 The images show cross-sectional views of the same first anti-finger terminal connector 56A and second anti-finger terminal connector 56B. Figure 5 yes Figure 4 An exploded view shows that each of the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B includes an upper terminal cap 78 and a lower terminal cap 80, the upper terminal cap 78 and the lower terminal cap 80 including features 82 and 84 adapted to secure the upper terminal cap 78 to the lower terminal cap 80, wherein a first distal end 54A or a second distal end 54B of the bus 52 is encapsulated therebetween. Figure 2 and Figure 3As shown, the lower terminal cap 80 of each of the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B includes a plurality of clips 82 that are received in corresponding slots 84 extending from the upper terminal cap 78 of each of the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B. This allows the upper terminal cap 78 and the lower terminal cap 80 to snap onto one of the first distal ends 54A and 54B of the busbar 52, wherein, once placed on the busbar 52, the clips 82 engage the slots 84, removably securing the upper terminal cap 78 to the lower terminal cap 80 and securing the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B to the busbar 52. Manually disengaging the clips 82 of the lower terminal cap 80 from the slots 84 of the upper terminal cap 78 allows the finger-resistant terminal connectors 56A and 56B to be removed from the busbar 52. Therefore, the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B can be reused multiple times. Figure 5 As shown, in another exemplary embodiment, the lower terminal cap 80 of each of the first finger-proof terminal connector 56A and the second finger-proof terminal connector 56B includes a plurality of slots 86 that receive corresponding clips 88 extending from the upper terminal cap 78 of each of the first finger-proof terminal connector 56A and the second finger-proof terminal connector 56B.

[0059] Each of the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B has an upper terminal cap 78 including a fastener retaining cap 90 having features 92 adapted to rotatably secure a terminal fastener 94 therein, wherein the terminal fastener 94 extends through a first groove 66A or a third groove 66B within the busbar 52. As shown, the head 96 of the terminal fastener 94 is held near the upper end 98 of the fastener retaining cap 90 by a plurality of inwardly extending flexible fingers 92. The fastener retaining cap 90 also includes an opening 100 formed therein to allow access to the head 96 of the terminal fastener 94. The terminal fastener 94 has an externally threaded shaft 102 adapted to engage a threaded hole 104 within an external terminal 58. Thus, referring to... Figure 7A When the upper terminal cap 78 and the lower terminal cap 80 are snapped onto the busbar 52, the terminal fastener 94 is suspended inside the fastener retaining cap 90, extending downward through the first groove 66A or the third groove 66B inside the busbar 52. Furthermore, when the anti-finger terminal connectors 56A and 56B are placed on the external terminal 58 of the battery module 60, the terminal fastener 94 aligns with the threaded hole 104 inside the external terminal 58 and is suspended above the threaded hole 104 inside the external terminal 58. Figure 7A As shown.

[0060] The opening 100 within the fastener retaining cap 90 allows a tool to approach the terminal fastener 94, wherein rotation of the terminal fastener 94 causes the external threaded shaft 102 of the terminal fastener 94 to engage the threaded hole 104 of the external terminal 58, wherein, as the terminal fastener 94 is screwed into the threaded hole 104 of the external terminal 58, the head 96 of the terminal fastener 94 is pulled out from the plurality of flexible fingers 92 and disengaged from the fastener retaining cap 90. When the terminal fastener 94 is fully screwed into the external terminal 58, the head 96 of the terminal fastener 94 engages the top surface 106 of the busbar 52 and pulls the busbar 52 downward toward the external terminal 58.

[0061] Each of the first finger-protection terminal connector 56A and the second finger-protection terminal connector 56B includes an alignment post 78 in its upper terminal cap 78. The alignment post 108 extends through a second slot 70A or a fourth slot 70B within the busbar 52 and engages with a limiting stop slot 110 formed in the lower terminal cap 80. When assembling the upper terminal cap 78 and the lower terminal cap 80, the alignment post 108 facilitates the alignment of the upper terminal cap 78 and the lower terminal cap 80 and provides structural rigidity to the finger-protection terminal connectors 56A and 56B after assembly.

[0062] The lower terminal cap 80 of each of the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B includes a terminal cylinder 112 supported within an alignment recess 114 formed therein. The alignment recess 114 is coaxially aligned with a first slot 66A / third slot 66B within the busbar 52, a terminal fastener 94, and a fastener retaining cap 90, and includes a radial retaining lip 116 adapted to engage a radial support lip 118 extending around the upper end 120 of the terminal cylinder 112 to support the terminal cylinder 112 therein.

[0063] Terminal sleeve 112 is adapted to engage an external terminal 58 and includes a contact surface 122 and a cylinder 124. The contact surface 122 contacts a busbar 52 and is adapted to establish an electrical connection therebetween. The cylinder 124 defines a terminal alignment hole 126 adapted to receive a hub 128 of the external terminal 58 therein. A terminal fastener 94 extends through an orifice 130 within the contact surface 122 of the terminal sleeve 112 to engage a threaded hole 104 of the hub 128 of the external terminal 58 and secure the busbar 52 to contact the contact surface 122 of the terminal sleeve 112. It also secures the bottom edge 132 of the body 124 of the terminal sleeve 112 to contact the conductive surface 134 of the external terminal 58, thereby establishing an electrical connection between the busbar 52 and the conductive surface 134 of the external terminal 58 through the terminal sleeve 112. In other embodiments, the finger-proof terminal connectors 56A and 56B are adapted to connect to external terminals having a flat conductive surface (without a hub), and can be used without the terminal sleeve 112, wherein the bus 52 directly contacts the flat conductive surface 134.

[0064] Refer again Figure 6 The width 136 and length 138 of the first slot 66A in the first distal end 54A of the busbar 52 and the third slot 66B in the second distal end 54B of the busbar 52 are both greater than the diameter 140 of the terminal fastener 94 extending through them. Furthermore, the width 142 and length 144 of the second slot 70A in the first distal end 54A of the busbar 52 and the fourth slot 70B in the second distal end 54B of the busbar 52 are both greater than the diameter 146 of the alignment post 108 extending through them. Therefore, after the upper terminal cap 78 and lower terminal cap 80 of the first finger-proof terminal connector 56A and the second finger-proof terminal connector 56B are assembled onto the first distal end 54A and the second distal end 54B of the bus 52, and before the terminal fastener 94 is secured to the external terminal 58, the first distal end 54A of the bus 52 is movable in the xy plane relative to the first finger-proof terminal connector 56A, and the second distal end 54B of the bus 52 is movable in the xy plane relative to the second finger-proof terminal connector 56B.

[0065] The width 136 of the first groove 66A and the third groove 66B within the busbar 52 is smaller than the diameter 148 of the head 96 of the terminal fastener 94. Therefore, when the terminal fastener 94 is screwed into the threaded hole 104 of the external terminal 58, the head 96 of the terminal fastener 94 engages the top surface 106 of the busbar 52 to pull the busbar 52 downward toward the external terminal 58.

[0066] The dimensional clearances between the first slot 66A and the third slot 66B and the terminal fastener 94, and between the third slot 70A and the fourth slot 70B and the alignment post 108, allow the distal ends 54A and 54B of the busbar 52 to slide back and forth within the xy plane defined by the x-axis 62 and the y-axis 64. This allows the busbar assembly 50 to accommodate dimensional errors and inaccurate placement and alignment of the modules and electrical components being interconnected.

[0067] Refer again Figure 2 and Figure 3 In an exemplary embodiment, the upper terminal cap 78 of each of the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B includes a first pick-and-place feature 150 adapted to allow the bus assembly 50 to be gripped by an automated tool. As shown, the first pick-and-place feature 150 is cross-shaped with intersecting fins, one fin aligned along the x-axis 64 and the other fin aligned along the y-axis. The cross-shaped first pick-and-place feature 150 defines a reference point or datum for a robot / automated tool to position the bus assembly 50. Furthermore, one or both fins of the first pick-and-place feature define a lifting interface onto which the gripping tool of the robot / automated tool attaches the bus assembly 50 for movement and positioning. Therefore, when the bus assembly 50 is supported by an automated tool gripping the first pick-and-place feature 150 of the upper terminal cap 78, the bus 52 can move relative to the finger-resistant terminal connectors 56A, 56B in the xy plane. For example, refer to... Figure 3When the automated tool grasps the first pick-and-place feature 150 of the first finger-proof connector 56A at the first distal end 54A of the busbar 52, the first pick-and-place feature 150 of the first finger-proof connector 56A becomes a reference reference for the automated tool to position the first finger-proof connector 56A for proper engagement with the external terminal 58 of the battery module 60. For the second finger-proof connector 56B to be connected to the external terminal of an adjacent battery module or ICB, the position and alignment of the adjacent battery module or ICB need to be precise so that the second finger-proof connector 56B is correctly aligned with the external terminal of the adjacent battery module or ICB. The degree of freedom of movement of the busbar 52 relative to the sliding plane of the first finger-proof connector 56A and the degree of freedom of movement of the second finger-proof connector 56B relative to the sliding plane of the busbar 52 allow the busbar 52 assembly to accommodate slight inaccuracies in the position of the adjacent battery module. After the first finger-proof connector 56A is connected to the external terminal 58 of the battery module 60, the first pick-and-place feature 150 of the second finger-proof connector 56B can then be used by the automated / robotic tool to grasp the first pick-and-place feature 150. When the automated tool grasps the first pick-and-place feature 150 of the second finger-resistant terminal connector 56B at the second distal end 54B of the busbar 52, the first pick-and-place feature 150 of the second finger-resistant terminal connector 56B defines a reference point or datum for positioning the second finger-resistant terminal connector 56B to properly engage with the external terminal 58 of the adjacent component. The sliding plane movement freedom of the busbar 52 relative to the first finger-resistant terminal connector 56A and the sliding plane movement freedom of the second finger-resistant terminal connector 56B relative to the busbar 52 allow the second finger-resistant terminal connector 56B to move relative to the first finger-resistant terminal connector 56A, thus allowing the automated / robotic tool to correctly position the second finger-resistant terminal connector 56B and accommodate slight inaccuracies in the position of the adjacent component, even after the first finger-resistant terminal connector 56A has been secured to the external terminal 58 of the battery module 60. Therefore, the busbar assembly 50 provides a robust assembly process that can accommodate positional inaccuracies and dimensional tolerances between adjacent battery modules and enables the automated (robotic) tool to assemble the busbar assembly 50 to adjacent modules.

[0068] Furthermore, in another exemplary embodiment, the protective outer coating 72 of the busbar 52 includes a second pick-and-place feature 152 adapted to allow the busbar assembly 50 to be gripped by an automated tool. As shown, the second pick-and-place feature 152 is cross-shaped with intersecting fins, one fin aligned along the x-axis 64 and the other fin aligned along the y-axis. The cross-shaped second pick-and-place feature 152 defines a reference point or datum for the robot / automated tool to position the busbar assembly 50. Additionally, one or both fins of the second pick-and-place feature define a lifting interface on which the gripping tool of the robot / automated tool secures the busbar assembly 50 for movement and positioning. Therefore, when the bus assembly 50 is supported by an automated tool of the second pick-up and place feature 152 that grips the protective outer coating 72 of the bus 52, the first finger-proof terminal connector 56A is movable relative to the bus 52 in the xy plane, and the second finger-proof terminal connector 56B is movable relative to the bus 52 in the xy plane.

[0069] For example, when the automated tool picks up the second pick-up and placement feature 152 of the bus 52, the second pick-up and placement feature 152 of the bus 52 becomes a reference point or benchmark for the automated tool. This reference point or benchmark is used to position the bus assembly 50 and therefore the first finger-protected terminal connector 56A to properly engage with the external terminals of the battery module or ICB, and to position the second finger-protected terminal connector 56B to properly engage with the external terminals of the adjacent battery module or ICB. Therefore, the position of the bus 52 is a control benchmark, which may be critical if the bus 52 is mounted on a structural feature within the vehicle 10. For the first finger-protected terminal connector 56A and the second finger-protected terminal connector 56B to connect to the external terminals of the adjacent battery module or ICB, the position of the adjacent battery module or ICB relative to the structural feature of the vehicle needs to be precise. The degree of freedom of movement of the first finger-protected terminal connector 56A relative to the sliding plane of the bus 52 allows the bus assembly 50 to accommodate slight inaccuracies in the position of the battery module or ICB to which the first finger-protected terminal connector 56A will be connected. The sliding plane movement freedom of the second finger-protected terminal connector 56B relative to the busbar 52 allows the busbar assembly 50 to accommodate slight inaccuracies in the position of the battery module or ICB to which the second finger-protected terminal connector 56B will be connected. Therefore, the busbar assembly 50 provides a robust assembly process that can accommodate positional inaccuracies and dimensional tolerances between adjacent battery modules, and enables automated (robotic) tools to assemble the busbar assembly 50 to adjacent modules, ICBs, or structural features of the vehicle 10.

[0070] In an exemplary embodiment, the fastener retaining cap 90 of each of the first finger-resistant terminal connector 56A and the second finger-resistant terminal connector 56B includes an external thread 154 adapted to engage an internal thread 156 of a self-ignition cap 158. The self-ignition cap 158 has a hexagonal shape adapted to allow manual or automatic engagement with a tool to selectively assemble or remove the self-ignition cap 158 from the fastener retaining cap 90. The self-ignition cap 158 is adapted to removably cover an opening 100 within the fastener retaining cap 90, the opening 100 being adapted to allow access to the terminal fastener 94. Thus, once the upper terminal cap 78 and the lower terminal cap 80 snap together, the distal ends 54A, 54B of the busbar 52 are enclosed therein, and the finger-resistant terminal connectors 56A, 56B are positioned on the external terminals 58, and the terminal fastener 94 is screwed into the external terminals 58, the self-ignition cap 158 is placed on the fastener retaining cap 90 to cover the opening 100 therein.

[0071] The protective outer coating 72, upper terminal cap 78, lower terminal cap 80 and self-ignition cap 158 of bus 52 are all made of non-conductive material, so that when bus assembly 50 is placed on adjacent modules to conduct current between them, bus assembly 50 prevents people or tools from accidentally coming into contact with the charged surface.

[0072] The busbar assembly 50 disclosed herein offers several advantages. These advantages include providing electrical insulation to charged surfaces when used for interconnecting electrical components and accommodating size, location, and alignment inaccuracies of modules interconnected with the busbar assembly 50, enabling the busbar assembly 50 to be robustly and automatically assembled to battery modules and ICBs.

[0073] The description in this disclosure is merely exemplary in nature, and any changes that do not depart from the spirit and scope of this disclosure are intended to fall within its scope. Such changes should not be considered as departing from the spirit and scope of this disclosure.

Claims

1. A busbar assembly for interconnecting components within a multi-module electrical system for vehicles, comprising: Busbar, the busbar having a first distal end and a second distal end; as well as A first finger-protection terminal connector is located on the first distal end of the bus and is adapted to electrically connect the bus to an external terminal, wherein the finger-protection terminal connector is adapted to allow limited movement of the first distal end of the bus relative to the first finger-protection terminal connector in the xy plane.

2. The busbar assembly according to claim 1, wherein, The busbar includes: A first groove is formed therein and longitudinally positioned along the central axis of the busbar, the first groove being adjacent to the first distal end of the busbar; A second groove formed therein and longitudinally positioned along the central axis of the generatrix, the second groove being adjacent to the first groove; and A protective outer coating extends along the length of the busbar, with the first distal end of the busbar including the first slot and the second slot extending beyond the protective outer coating, wherein the anti-finger terminal connector package includes the first distal end of the busbar including the first slot and the second slot, and extends on a first edge of the protective outer coating.

3. The busbar assembly according to claim 2, wherein, The first finger-proof terminal connector includes: An upper terminal cap and a lower terminal cap, the upper terminal cap and the lower terminal cap including features adapted to secure the upper terminal cap to the lower terminal cap, wherein the first distal end of the busbar is encapsulated therebetween; The upper terminal cap of the first finger-resistant terminal connector includes: A fastener retaining cap having features adapted to rotatably secure a terminal fastener therein, wherein the terminal fastener extends through a first groove within the busbar; Alignment post, the alignment post extending through the second groove in the busbar and engaging with the limiting stop groove formed in the lower terminal cap; The lower terminal cap of the first anti-finger terminal connector includes a terminal tube supported in an alignment recess formed therein, the terminal tube being adapted to engage an external terminal and including a contact surface that contacts the busbar and is adapted to establish an electrical connection therebetween, wherein the terminal fastener extends through the contact surface of the terminal tube and is adapted to engage the external terminal and secure the first distal end of the busbar and the first anti-finger terminal connector to the external terminal, and an electrical connection is established between the busbar and the external terminal through the terminal tube.

4. The busbar assembly according to claim 3, wherein, The width and length of the first slot are both greater than the diameter of the terminal fastener extending through it, and the width and length of the second slot are both greater than the diameter of the alignment post extending through it, wherein the first distal end of the busbar is movable relative to the first anti-finger terminal connector in the xy plane before the terminal fastener is fixed to the external terminal.

5. The busbar assembly according to claim 4, wherein, The upper terminal cap of the first finger-protection terminal connector includes a pick-up and placement feature adapted to allow the bus assembly to be gripped by an automated tool, wherein the bus is movable relative to the first finger-protection terminal connector in the xy plane when the bus assembly is supported by the automated tool gripping the pick-up and placement feature of the upper terminal cap of the first finger-protection terminal connector.

6. The busbar assembly according to claim 5, wherein, The outer protective cover of the busbar includes pick-up and placement features adapted to allow the busbar assembly to be gripped by an automated tool, wherein, when the busbar assembly is supported by the automated tool gripping the protective outer coating of the busbar by the pick-up and placement features, the first finger-proof terminal connector is movable relative to the busbar in the xy plane.

7. The busbar assembly according to claim 6, wherein, The bus assembly further includes a second finger-protected terminal connector located on the second distal end of the bus and adapted to electrically connect the bus to an external terminal, wherein the second finger-protected terminal connector is adapted to allow limited movement of the second distal end of the bus relative to the second finger-protected terminal connector in the xy plane.

8. The busbar assembly according to claim 7, wherein, The busbar includes: A third groove formed therein and longitudinally positioned along the central axis of the busbar, the third groove being adjacent to the second distal end of the busbar; and A fourth groove is formed therein and longitudinally positioned along the central axis of the generatrix, the fourth groove being adjacent to the third groove; and The protective outer coating extends along the length of the busbar, and the second distal end of the busbar including the third and fourth slots extends beyond the protective outer coating. The second finger-proof terminal connector package includes the second distal end of the busbar including the third and fourth slots and extends on the second edge of the protective outer coating.

9. The busbar assembly according to claim 8, wherein, The second finger-proof terminal connector includes: An upper terminal cap and a lower terminal cap, the upper terminal cap and the lower terminal cap including features adapted to secure the upper cap to the lower cap, wherein a second distal end of the busbar is encapsulated therebetween; The upper terminal cap of the second finger-proof terminal connector includes: A fastener retaining cap having features adapted to rotatably secure a terminal fastener therein, wherein the terminal fastener extends through the third groove within the busbar; Alignment post, which extends through a fourth groove within the busbar and engages with a limiting stop groove formed within the lower terminal cap of the second anti-finger terminal connector; The lower terminal cap of the second finger-proof terminal connector includes a terminal tube supported in an alignment recess formed therein, the terminal tube being adapted to engage an external terminal and including a contact surface that contacts the busbar and is adapted to establish an electrical connection therebetween, wherein the terminal fastener extends through the contact surface of the terminal tube and is adapted to engage the external terminal and secure a second distal end of the busbar and the second finger-proof terminal connector to the external terminal, and an electrical connection is established between the busbar and the external terminal through the terminal tube.

10. The busbar assembly according to claim 9, wherein, The width and length of the third slot are both greater than the diameter of the terminal fastener extending through it, and the width and length of the fourth slot are both greater than the diameter of the alignment post extending through it, wherein the second distal end of the busbar is movable relative to the second anti-finger terminal connector in the xy plane before the terminal fastener is fixed to the external terminal.

Images