Battery Cell Connector Contacting Element for Automated Assembly
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Solution Overview
Problem
In battery systems with multiple cells, automated laying and contacting of cell voltage measuring lines are challenging due to limited space and risk of mechanical damage, requiring a solution for reliable assembly with minimal mechanical stress.
Innovation Solution
A battery system design featuring contacting elements with auxiliary devices that allow parallel insertion and displacement of conductors to establish electrical connections without mechanical stress, using contacting tools to support force directly on the elements, and a method for producing an electrically conductive connection that reduces the risk of damage to cells and electronics units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the contacting section of the cell voltage measuring line protrudes beyond the edge of the cell connector to achieve good accessibility, then automated laying and contacting becomes easier, but the dimensions of the battery system increase
Solution Approach 1:
The patent changes the spatial arrangement by allowing the conductor to be inserted parallel to the base area of the cell connector through openings in the contacting element, rather than requiring perpendicular access from the edge. This dimensional change enables automated contacting tools to access the conductor through the body of the contacting element without increasing the overall footprint of the battery system.
2Adaptability or versatility
If manual laying and contacting of cell voltage measuring lines is performed, then flexibility is maintained, but assembly reliability decreases due to incorrect laying and poor contact
Solution Approach 1:
The patent changes the geometric parameters of the contacting interface by providing openings in the contacting element that are oriented parallel to the base area, allowing standardized automated tools to reliably insert and contact conductors. This parameter change enables automated processes while maintaining the flexibility needed for proper contact establishment.
3Reliability
If high contact force is applied to ensure reliable electrical connection, then contact reliability improves, but mechanical damage to cells and electronics unit increases
Solution Approach 1:
The patent introduces the contacting element as an intermediary component between the conductor and the cells/electronics unit. The contacting element absorbs and distributes the contact force through its structure and openings, allowing reliable electrical connection to be established without transmitting excessive mechanical stress to the fragile cells and electronics unit.
4Ease of manufacture
If the conductor is inserted perpendicular to the base area for easy alignment, then positioning becomes simpler, but mechanical stress on the contacting elements increases
Solution Approach 1:
The patent specifies that openings in the contacting element are oriented parallel to the base area, changing the insertion direction from perpendicular to parallel. This dimensional change allows automated tools to align and insert conductors while the contacting element structure distributes the resulting forces more favorably, reducing mechanical stress on the contacting elements themselves.
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
Enables process-reliable and automated assembly of cell voltage measuring lines with reduced dimensions and minimal mechanical loads, ensuring stable connections and preventing damage to the battery system components.
Implementation Method 1
first contact members which are formed on the first and second contacting element and are designed to penetrate the insulation of the conductor at least in sections and / or the conductor at least abschn ittwise to be deformed
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Battery system comprising a plurality of cells (1.1, 1.2) arranged in at least one stack, wherein a first pole (1.1.P1) of a first cell (1.1) is electrically connected to a second pole (1.2.P2) of a second cell (1.2) by a cell connector (3), an electronic unit (5) configured to detect the voltage of the cells (1.1, 1.2), wherein a first contact element (4.1) is arranged on the cell connector (3) and a second contact element (4.2) is arranged on the electronic unit (5), and a conductor (6), wherein a first section (6.1) of the conductor (6) is electrically connected to the first contact element (4.1) and a second section (6.2) of the conductor (6) is electrically connected to the second contact element (4.2), wherein the contacting of the conductor (6) with the first and the second contact elements (4.1, 4.2) is facilitated by means of a first contact elements (7) are located at the first and second contacting element (4.1, 4.2) are designed and configured to penetrate the insulation of the conductor (6) at least section by section and to deform the conductor (6) at least section by section, wherein the first contacting element (4.1) has a first opening (4.10) and the second contacting element (4.2) has a second opening (4.20) into which the conductor (6) can be inserted for contact with the first contact members (7), wherein the first opening (4.10) is oriented such that the first section (6.1) of the conductor (6) can be inserted parallel to the base (3G) of the cell connector (3) and that the second opening (4.20) is oriented such that the second section (6.2) of the conductor (6) can be inserted parallel to the base (5G) of the electronic unit (5), and methods for producing an electrically conductive connection.