Battery Pack Clamping Contact for Cell Stack Alignment Tolerance
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Solution Overview
Problem
Existing electrical connection systems for traction battery packs face challenges in securely and efficiently connecting components across different cell stacks, which can lead to alignment issues, build tolerances, and service complications.
Innovation Solution
The proposed electrical connection system includes a clamping electrical contact with a C-shape and a mechanical fastener that secures the clamped electrical contact between the flanges of the clamping contact, ensuring reliable electrical connections between busbars and batteries across different cell stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connection systems are used to connect components across different cell stacks, then alignment issues and build tolerance problems occur, but the connection reliability deteriorates
Solution Approach 1:
The electrical connection system incorporates movable electrical contacts that can dynamically adjust their position to accommodate alignment variations and build tolerances. The contacts are designed to move within a range of positions while maintaining electrical connection, allowing the system to adapt to manufacturing variations without compromising connection reliability
Solution Approach 2:
The system changes the positional parameters of the electrical contacts to optimize connection reliability. By allowing the contacts to vary their position within certain ranges and adjusting their coordinates dynamically, the system can compensate for alignment issues and build tolerance problems while maintaining reliable electrical connections
2Reliability
If complex electrical connection systems are used to ensure reliable connections, then connection reliability improves, but serviceability and ease of operation worsen
Solution Approach 1:
The electrical connection system is divided into modular segments including separate electrical contacts, busbars, and connection elements. Each component can be independently serviced, replaced, or adjusted, improving ease of operation and serviceability while maintaining connection reliability through the modular architecture
Solution Approach 2:
The electrical connection system incorporates self-adjusting features where the movable contacts automatically position themselves to maintain optimal electrical connection. This self-service capability reduces the need for manual adjustment and complex servicing procedures while ensuring reliable connections
Data Source
AI summary
An electrical connection system for a traction battery pack includes a clamping electrical contact having a first flange and a second flange, a clamped electrical contact, and a mechanical fastener that is secured to clamp the clamped electrical contact between the first flange of the clamping electrical contact and the second flange of the clamping electrical contact.