Traction Battery Busbar Locking Bar for Vibration Constraint
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Solution Overview
Problem
Existing traction battery packs face challenges in constraining busbar assemblies to prevent vibrations and movement, which can lead to structural instability and potential damage during vehicle operation.
Innovation Solution
A locking bar system is employed to constrain busbar assemblies within a traction battery pack by using apertures to receive fingers of the busbar frame, thereby inhibiting movement and vibrations, and is secured to compressive structures for added stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If busbar assemblies are left unconstrained in the battery pack, then ease of assembly is improved, but structural stability deteriorates due to vibrations and movement
Solution Approach 1:
The locking bar is pre-positioned with apertures aligned to receive the fingers of the busbar frame. This preliminary arrangement allows the busbar assembly to be constrained automatically during the assembly process without requiring additional steps to secure it, thus maintaining ease of assembly while achieving structural stability.
Solution Approach 2:
The locking bar acts as an intermediary component between the busbar assembly and the battery pack structure. It mediates the connection by receiving the fingers of the busbar frame through its apertures, thereby transferring and distributing mechanical constraints to stabilize the busbar assembly without requiring direct complex fastening mechanisms.
2Stability of the object's composition
If locking bars with multiple apertures are used to constrain busbar assemblies, then structural stability is improved, but device complexity increases
Solution Approach 1:
The locking bar is segmented with multiple apertures distributed along its length, each aperture corresponding to a specific finger of the busbar frame. This segmentation allows independent constraint of each finger while maintaining a simple, unified locking bar structure, thus achieving structural stability without significantly increasing device complexity.
Solution Approach 2:
The locking bar serves multiple functions simultaneously: it provides structural support, constrains multiple fingers of the busbar frame through its apertures, and distributes mechanical loads across the busbar assembly. This multi-functionality reduces the need for additional separate components, thereby maintaining simplicity while achieving comprehensive structural stability.
3Stability of the object's composition
If busbar assemblies are rigidly fixed to prevent all movement, then structural stability is improved, but adaptability deteriorates for vibration absorption
Solution Approach 1:
The locking bar provides a dynamic constraint system where the apertures allow controlled movement of the busbar fingers within certain limits. This dynamic arrangement enables the busbar assembly to absorb vibrations through small displacements while maintaining overall structural stability, avoiding the rigidity that would prevent vibration absorption.
Solution Approach 2:
The design changes the constraint parameter from complete rigidity to controlled flexibility. The apertures in the locking bar create a parameter range that allows limited movement for vibration absorption while maintaining sufficient constraint for structural stability, thus adapting the system's mechanical properties to meet both requirements.
Data Source
AI summary
A traction battery pack assembly includes a busbar assembly having at a frame and at least one busbar. The frame includes a plurality of fingers. A locking bar has a plurality of apertures that are each configured to receive a portion of one or more of the fingers to constrain the busbar assembly.