Battery Module Fuse Assembly for Easier Bus Bar Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Managing battery modules with multiple fuses adjacent to bus bars becomes difficult in the event of a fuse failure, complicating fuse replacement.
Innovation Solution
A battery module design featuring a fuse assembly with a fuse frame, fuse connector, and bus bar connector that includes bus bar connector legs electrically connected to fuse segments, facilitating easy replacement and integration with a sensing frame and safety cap for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fuses are positioned adjacent to the bus bar, then electrical connection is achieved, but fuse management and replacement become difficult
Solution Approach 1:
The fuse assembly is segmented into multiple fuse segments (first fuse segment, second fuse segment, etc.) that are arranged in series between the first bus bar and second bus bar. Each fuse segment can be independently identified and replaced, solving the management difficulty while maintaining electrical connection reliability.
Solution Approach 2:
A fuse holder is introduced as an intermediary component that accommodates multiple fuse segments and provides a unified mounting structure to the bus bar. This mediator allows individual fuse segments to be accessed and replaced without disturbing the entire assembly, improving ease of operation while maintaining reliable electrical connections.
2Device complexity
If fuses are directly connected to bus bars, then electrical connection is simple, but fuse replacement complicates bus bar management
Solution Approach 1:
The connection structure is segmented into distinct functional components: fuse segments for protection, a fuse holder for mounting, and bus bar connector legs for electrical connection. This segmentation allows fuse segments to be replaced independently without affecting the bus bar connector or other fuses, improving ease of repair while maintaining manageable device complexity.
Solution Approach 2:
The fuse holder is pre-configured with multiple fuse segments arranged in series between specific bus bar connector legs. This preliminary arrangement allows for systematic fuse replacement where failed segments can be identified and swapped without reconfiguring the entire connection structure, facilitating easier repair while keeping the overall device complexity manageable.
Data Source
AI summary
According to an aspect of the present invention, there is provided a battery module including: a plurality of battery cells; a plurality of bus bars connected to the plurality of battery cells; a fuse assembly; and a bus bar connector configured to electrically connect the plurality of bus bars and the fuse assembly, wherein the fuse assembly may include: a fuse frame; a fuse connector coupled to the fuse frame and connected to the bus bar connector, and a plurality of fuse segments coupled to the fuse connector and electrically connected to the fuse connector.