Battery Connection Member Wiring Part Segmentation
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Solution Overview
Problem
The existing battery connection plates face challenges in downsizing the wiring groove due to signal line interference with terminal swaging parts, leading to increased material and mold costs.
Innovation Solution
A battery connection member with a wiring part that includes a communication part and an electric wire protection part, where the electric wire is bent near the terminal's swaging part and protected from contact with other terminals, allowing for flexible wiring directions and preventing terminal contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the wiring groove is enlarged to accommodate signal lines avoiding terminal swaging parts, then the signal lines can be properly routed without interference, but the battery connection plate size increases leading to higher material and mold costs
Solution Approach 1:
The wiring groove is divided into two functional segments: a communication part that allows signal lines to pass through near terminal swaging parts, and a wiring part that provides protected routing space. This segmentation enables proper signal line routing without requiring the entire groove to be enlarged, thus solving the contradiction between wiring accessibility and compact size.
Solution Approach 2:
An electric wire protection part is introduced as an intermediary element within the wiring groove. This protection part physically separates and protects signal lines from terminal swaging parts, allowing the wiring groove to maintain a compact size while still enabling safe and effective signal line routing without interference.
2Ease of manufacture
If the wiring groove is downsized to reduce material and mold costs, then manufacturing costs decrease, but signal lines may contact terminal swaging parts causing interference
Solution Approach 1:
The electric wire protection part serves as a mediator between signal lines and terminal swaging parts. It maintains electrical isolation and physical separation, ensuring reliable electrical connections while allowing the wiring groove to be downsized for cost-effective manufacturing.
Solution Approach 2:
The protection function is extracted as a separate electric wire protection part rather than relying on the wiring groove structure alone. This extracted protection element ensures signal line isolation from terminals, enabling the overall assembly to be compact while maintaining reliability.
3Adaptability or versatility
If the wiring groove is enlarged to provide routing space for signal lines, then wiring flexibility increases, but the battery connection plate requires more material and larger mold size
Solution Approach 1:
The wiring groove is segmented into communication and wiring parts with distinct functions. The communication part enables wiring flexibility by allowing signal lines to pass through, while the wiring part provides protected routing space. This segmentation achieves wiring adaptability without requiring excessive material or large mold size.
Solution Approach 2:
The wiring groove utilizes three-dimensional space efficiently by creating vertical depth (wiring part) in addition to horizontal routing (communication part). This dimensional approach provides wiring flexibility and protection without increasing the overall footprint or material quantity of the battery connection plate.
Data Source
AI summary
Prevention of interference between an electric wire and a terminal in a wiring part, and downsizing of the wiring part are achieved. A battery connection member, includes a plurality of housings accommodating a bus bar connecting in series a plurality of batteries, and one or more terminals electrically connected to the bus bar; and a wiring part arranged in parallel along the plurality of housings in a direction intersecting a connecting direction of the electric wire relative to the terminals. The wiring part includes: a communication part formed to communicate with inside the wiring part, and positioning an end of a swaging part of the terminal therein; and an electric wire protection part continuing to the communication part, projecting toward inside the wiring part, and formed to prevent contact of the terminal positioned inside the communication part and the electric wire connected to the other terminal.