Battery Pack Busbar Assembly for Resistance-Based Connection Verification
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Solution Overview
Problem
Insufficiently secured busbar assemblies in battery packs lead to ineffective current transfer, making it difficult to verify proper connections without relying on torque and angle measurements of fasteners.
Innovation Solution
A busbar assembly with strategically placed openings in a casing that exposes portions of the busbars, allowing probes to measure resistance across the assembly, ensuring secure connections without relying on fastener torque and angle verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar assembly is fully enclosed in the casing, then the structural integrity and safety are improved, but the accessibility for measurement and verification is worsened
Solution Approach 1:
The casing is segmented with specific openings at defined positions to expose portions of the busbars. This segmentation allows the casing to maintain its protective enclosure function while providing targeted access points for measurement, resolving the contradiction between full enclosure and measurement accessibility.
Solution Approach 2:
The openings in the casing act as intermediaries that allow measurement tools to access the busbars without compromising the overall enclosure. This mediator approach enables verification of connection security while maintaining the protective function of the casing.
2Reliability
If torque and angle measurements of fasteners are used to verify connections, then the connection security can be assessed, but the measurement complexity and time consumption increase
Solution Approach 1:
The patent replaces mechanical verification methods (torque and angle measurements of fasteners) with electrical measurement methods (resistance measurement through openings). This substitution simplifies the verification process by directly measuring the electrical connection quality rather than inferring it from mechanical fastener parameters.
Solution Approach 2:
The busbar assembly design incorporates the verification capability directly into its structure through the openings in the casing. This self-service approach allows the assembly to be easily verified without requiring external complex measurement equipment or procedures, reducing verification time while maintaining reliability.
3Productivity
If the busbar assembly allows easy access for measurement, then the verification efficiency is improved, but the structural protection and safety are worsened
Solution Approach 1:
The casing is segmented with specific openings at defined positions to expose portions of the busbars. This segmentation allows the casing to maintain its protective enclosure function while providing targeted access points for measurement, resolving the contradiction between full enclosure and measurement accessibility.
Solution Approach 2:
The openings are strategically positioned to expose only the specific portions of the busbars that need to be measured, while the rest of the busbar assembly remains protected by the casing. This local quality approach ensures that measurement accessibility is provided only where necessary, maintaining overall structural protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates easy verification of secure busbar connections during manufacturing and maintenance by providing accessible points for resistance measurement, ensuring adequate electrical connections within battery packs.
Implementation Method 1
measuring a resistance across the busbar assembly
Data Source
AI summary
The apparatus can include a member and an end portion. The end portion can be disposed at an end of the member. The end portion can include a first opening and a second opening. The first opening can be configured to expose a portion of a first busbar. The second opening can be configured to expose a portion of a second busbar. The first busbar can be configured to couple with the second busbar.