Battery Cover Opening for Visible Bus Bar Terminal Connection
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Solution Overview
Problem
The existing battery assembly structures make it difficult to visually confirm the relative positional relationship between the bus bar and the terminal, leading to challenges in connecting them without interference or damage during wiring work.
Innovation Solution
The battery assembly structure includes a battery cover with an opening part that allows visibility of the bus bar and terminal, enabling easy connection by positioning the bus bar and terminal such that they are visible through the opening, facilitating their electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery cover is assembled to cover the accommodation part, then the structural integrity and protection are improved, but the visibility of the bus bar and terminal for connection work deteriorates
Solution Approach 1:
The battery cover is segmented by introducing an observation window that is openable, allowing the cover to be divided into a fixed portion and a movable observation portion. This enables the operator to open the observation window to visually confirm the relative positional relationship between the bus bar and terminal, while maintaining the protective function of the closed cover.
Solution Approach 2:
An observation window serves as an intermediary mechanism between the operator and the internal components (bus bar and terminal). This window allows visual access to the connection area without requiring full disassembly of the battery cover, thus maintaining structural integrity while enabling connection work.
2Device complexity
If the opening part extends through in the up-down direction, then the structural simplicity is maintained, but the visibility of the bus bar and terminal for wiring work deteriorates
Solution Approach 1:
The observation window is configured to extend in the width direction (horizontal dimension) rather than only in the up-down direction. This dimensional change provides a broader viewing angle that allows simultaneous visual confirmation of both the bus bar and terminal, improving visibility for connection work while maintaining structural simplicity.
3Reliability
If the battery cover fully covers the accommodation part, then the protection and enclosure are improved, but the accessibility for connection work deteriorates
Solution Approach 1:
The observation window is designed to be opened beforehand to allow visual confirmation of the relative positional relationship between the bus bar and terminal before connection work begins. This preliminary visual assessment enables operators to plan their connection approach, preventing interference or damage during the actual connection process while maintaining full enclosure protection.
Data Source
AI summary
A battery assembly structure includes: a battery case including an accommodation part configured to accommodate a battery pack; a battery cover including a wall part covering the accommodation part, and an opening part extending through the wall part; a connector disposed on an outer surface side of the wall part; and a bus bar disposed on an inner surface side of the wall part and configured to electrically connect the connector and a terminal disposed in the battery pack. In a case where the battery cover is assembled to the battery case such that the accommodation part is covered by the wall part, the opening part is disposed in a position in which the bus bar and the terminal are visible through the opening part from the outer surface side of the wall part.