Battery Cell Connector Assembly for Error-Free Pack Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack connector structures for electric gardening and forestry devices are complex to assemble and lack automation, leading to potential assembly errors and difficulties in securing defective components, which can result in critical conditions.
Innovation Solution
A cell connector structure with pre-assembled components, including cell connectors and voltage tapping elements, designed for direct and secure arrangement, enabling simple, tool-free assembly and high automation, with features like snap connections and color-coded cables to prevent incorrect assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional connector structures are used for battery packs, then electrical connection is achieved, but assembly complexity increases and automation becomes difficult
Solution Approach 1:
The connector structure is divided into separate functional modules: cell connectors for electrical connection, voltage tapping elements for monitoring, and securing elements for mechanical attachment. This segmentation allows each module to be manufactured and assembled independently, enabling automation while reducing overall assembly complexity.
Solution Approach 2:
The cell connectors and voltage tapping elements are pre-assembled into a integrated connector assembly before being installed in the battery pack. This preliminary assembly simplifies the final installation step and enables automated assembly processes by reducing the number of discrete components that need to be handled during final assembly.
2Ease of operation
If complex connector structures are used, then electrical connections are secured, but assembly errors increase and tool-free assembly becomes difficult
Solution Approach 1:
The connector assembly incorporates self-aligning features and snap-fit mechanisms that enable the connectors and voltage tapping elements to automatically position themselves correctly during assembly. This self-service capability allows tool-free assembly while maintaining connection reliability through precise mechanical engagement.
Solution Approach 2:
Different colored cables and connectors are used to indicate positive and negative polarity connections. This visual differentiation prevents assembly errors by making it immediately obvious which connectors should be connected together, thereby maintaining reliability while simplifying the assembly process.
3Ease of repair
If traditional assembly methods are used, then components are connected, but defective components cannot be easily secured or replaced
Solution Approach 1:
The connector assembly is designed as a modular unit with individual cell connectors and voltage tapping elements that can be independently accessed and replaced. The securing elements are designed to release and re-engage easily, allowing defective components to be quickly replaced without compromising the overall connection reliability or system safety.
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a cell connector assembly (1) for a battery pack (111) for supplying an electrically powered garden and/or forestry work tool (101) with electrical drive power (AL), wherein the cell connector assembly (1) comprises: - a plurality of cell connectors (2a, 2b, 2c), wherein the cell connectors (2a, 2b, 2c) are designed for electrically connecting accumulator cells (114a, 114b, 114c), - at least one cell connector element (3a, 3b), wherein the cell connectors (2a, 2b, 2c) and the at least one cell connector element (3a, 3b) are designed for arrangement one another and for securing them against detachment from one another, - a plurality of voltage tap elements (4), wherein the voltage tap elements (4) have voltage tap cables (5), wherein the voltage tap cables (5) are for electrical connection with the cell connectors (2a, 2b, 2c) are formed, and - at least one tap element body (6a, 6b),wherein the voltage tap elements (4) and the at least one tap element body (6a, 6b) are designed for arrangement on one another and for securing against detachment from one another, - wherein the at least one cell connector element (3a, 3b) with the cell connectors (2a, 2b, 2c) and the at least one tap element body (6a, 6b) with the voltage tap elements (4) are designed for mechanical connection to one another.