Battery Connecting Assembly Hinged Cover Design
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Solution Overview
Problem
The existing battery connecting assemblies for electric vehicles face challenges in preventing short circuits due to foreign obstacles and incur increased manufacturing costs as the number of batteries grows, as separate covers for each connection unit become cumbersome and require larger molds.
Innovation Solution
A battery connecting assembly with integral connection unit covers, featuring a hinge and stopper mechanisms that allow for efficient alignment and connection of multiple units with a single mold, reducing the need for larger molds and simplifying the assembly process by allowing all covers to be closed in a single operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate cover is formed to cover the whole battery connecting assembly, then foreign obstacles are less likely to contact the connection member and electrode terminals, but the mold size increases and manufacturing cost increases
Solution Approach 1:
The battery connecting assembly is divided into multiple connection units, each with its own cover. This segmentation allows each cover to be molded separately with a smaller mold, reducing mold manufacturing cost while still providing comprehensive protection against foreign obstacles.
2Reliability
If connection member covers are integrally provided with each connection unit, then foreign obstacles are less likely to contact the connection member, but the closing operation becomes extremely troublesome as the number of batteries increases
Solution Approach 1:
Adjacent connection units are coupled together through their covers, which are connected via hinges. This merging allows multiple covers to be closed simultaneously in a single operation, significantly reducing the complexity of the closing operation even as the number of batteries increases.
Solution Approach 2:
The covers are designed with hinges that allow them to be dynamically opened and closed. The hinge mechanism enables the covers to be folded back during assembly and then closed together in one operation, making the process adaptable to varying numbers of batteries without increasing complexity.
3Adaptability or versatility
If the number of connection units is increased to accommodate more batteries, then the battery connecting assembly can handle larger battery modules, but the complexity of closing each cover individually increases
Solution Approach 1:
The covers of adjacent connection units are mechanically coupled together through hinges and connection portions. This merging allows the covers to move and close in unison, enabling the system to accommodate varying numbers of batteries without proportionally increasing the closing operation complexity.
Solution Approach 2:
The hinge and cover connection mechanism serves multiple functions: it allows individual cover movement for assembly, enables simultaneous closing of multiple covers, and provides structural connection between adjacent connection units. This multi-functionality makes the system versatile for different battery configurations.
Data Source
AI summary
Each of connection units integrally includes a cover via a hinge, and the cover covers an accommodation portion in which a connecting member is arranged. The connection unit includes a unit stopper and a unit stopper receiver that is fitted to the unit stopper that is formed on an adjacent connection unit. The cover includes a cover stopper and a cover stopper receiver that is fitted to the cover stopper formed on the cover of the adjacent connection unit. The connection units are connected to each other by fitting of the unit stoppers and the unit stopper receivers and fitting of the cover stoppers and the cover stopper receivers.