Battery Alignment Plate and Interface for Connector Precision
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Solution Overview
Problem
Maintaining proper alignment and mechanical support of electrical connections between batteries and battery management systems is challenging due to manufacturing variances and vibration, affecting the reliability and ease of assembly.
Innovation Solution
A rechargeable battery system with an alignment plate and a battery management system featuring alignment pins and an interface plate to ensure precise alignment and secure mating of electrical connectors, including a die-cast housing with press-fit alignment pins and an insulator for stability and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional electrical connectors are used without alignment features, then the device complexity is reduced, but the manufacturing precision and reliability of electrical connections deteriorate due to manufacturing variances and vibration
Solution Approach 1:
Alignment pins and alignment plate apertures are pre-positioned during manufacturing to establish predetermined alignment relationships between the battery connector and battery management system connector. This preliminary positioning ensures that when components are assembled, the electrical contacts automatically align correctly without requiring complex adjustment mechanisms during assembly.
Solution Approach 2:
The alignment plate serves as an intermediary component between the battery connector and the battery management system connector. It provides a stable reference surface with precisely positioned apertures that guide the alignment pins, thereby mediating the alignment process and ensuring accurate electrical connection without requiring direct precision machining between mating components.
2Reliability
If alignment features are added to ensure proper alignment, then the reliability of electrical connections is improved, but the ease of manufacture deteriorates due to additional manufacturing steps
Solution Approach 1:
The alignment pins and alignment plate apertures create a self-aligning mechanism where the components guide themselves into the correct position during assembly. The alignment pins automatically engage with the apertures in the alignment plate, causing the connector to self-position without requiring external alignment tools or complex manual adjustment procedures.
Solution Approach 2:
The alignment features are pre-manufactured into the components with precise tolerances. The alignment plate is manufactured with accurately positioned apertures, and the alignment pins are manufactured to matching tolerances, so that when assembled, they automatically provide the necessary alignment without requiring additional manufacturing steps or adjustments during final assembly.
3Reliability
If mechanical support structures are added to maintain alignment under vibration, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The alignment plate combines multiple functions into a single component: it provides mechanical support for the battery connector, establishes precise alignment through its apertures, and serves as a mounting surface for the battery management system. This merging of functions eliminates the need for separate alignment fixtures, mounting brackets, and support structures that would otherwise be required.
Solution Approach 2:
The alignment plate serves multiple purposes within the battery assembly: it acts as a structural support element, an alignment reference surface, a mounting platform for the battery management system, and a guide for electrical connector insertion. This multi-functionality reduces the overall number of components needed in the assembly while maintaining reliability under vibration.
Data Source
AI summary
A rechargeable battery system is disclosed. In an embodiment, the rechargeable battery system includes a rechargeable battery having a first electrical connector, an alignment plate mounted to the rechargeable battery, wherein the first electrical connector is aligned to the alignment plate, a battery management system having a second electrical connector configured to mate with the first electrical connector, wherein the second electrical connector comprises a housing, at least one alignment pin secured to the housing, and an electrical contact, wherein the alignment pin is disposed in the housing in a determined position relative to the electrical contact, and an interface plate having a first interface portion and a second interface portion wherein the first interface portion is configured to mate with the alignment plate and wherein the second interface portion is configured to mate with the alignment pin to align the first electrical connector with the second electrical connector.