Adjustable Inter-Bus Bar for Variable Battery Module Spacing
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Solution Overview
Problem
Existing inter-bus bars are not adaptable to varying distances between battery modules, requiring separate manufacturing for each battery pack model, which limits compatibility and increases production costs.
Innovation Solution
A length-adjustable inter-bus bar design comprising two bus bars with adjustable length regions that can be coupled and decoupled, allowing for adjustable overlap and secure electrical connection regardless of module spacing, using features like keyholes, fitting buttons, and screwing mechanisms to achieve precise length adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inter-bus bars are manufactured with different lengths for each battery pack model, then the connection accuracy between battery modules is improved, but the manufacturing complexity and inventory requirements increase
Solution Approach 1:
The inter-bus bar incorporates an adjustable length mechanism where the second bus bar can be positioned at different locations along the first bus bar's length. This dynamic adjustment capability allows a single standardized inter-bus bar design to accommodate varying distances between battery modules across different pack models, eliminating the need to manufacture multiple fixed-length variants while maintaining precise connection accuracy.
Solution Approach 2:
The inter-bus bar design enables one standardized component to serve multiple functions across different battery pack models. By allowing the second bus bar to be positioned at various locations along the first bus bar, a single universal inter-bus bar design can adapt to different module spacing requirements, replacing the need for model-specific customized lengths.
2Adaptability or versatility
If inter-bus bars are manufactured with different lengths for each battery pack model, then the fit for specific models is improved, but the production cost and inventory management difficulty increase
Solution Approach 1:
The inter-bus bar incorporates an adjustable length mechanism where the second bus bar can be positioned at different locations along the first bus bar's length. This dynamic adjustment capability allows a single standardized inter-bus bar design to accommodate varying distances between battery modules across different pack models, eliminating the need to manufacture multiple fixed-length variants while maintaining precise connection accuracy.
3Ease of manufacture
If fixed-length inter-bus bars are used, then the manufacturing process is simplified, but the adaptability to varying battery module distances is reduced
Solution Approach 1:
The inter-bus bar incorporates an adjustable length mechanism where the second bus bar can be positioned at different locations along the first bus bar's length. This dynamic adjustment capability allows a single standardized inter-bus bar design to accommodate varying distances between battery modules across different pack models, eliminating the need to manufacture multiple fixed-length variants while maintaining precise connection accuracy.
Data Source
AI summary
An inter-bus bar including a first bus bar including a first body region having a fastening hole formed at one end and a first length adjusting region configured to extend by a predetermined length from the other end, and a second bus bar including a second body region having a fastening hole formed at one end and a second length adjusting region configured to extend by a predetermined length from the other end, the second bus bar being configured to be coupled to or released from the first bus bar, the first length adjusting region and the second length adjusting region forming a connection portion where they are at least partially overlapped, and the first length adjusting region and the second length adjusting region being removably coupled to each other at different relative positions to change the length of the connection portion.