Battery Module Wire Harness Layout for Cell Stability at Bends
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Solution Overview
Problem
Battery modules face challenges in maintaining the regularity and stability of battery cells during operation and transportation due to high bending stress and limited wiring space, leading to difficulty in handling and potential scattering of cells.
Innovation Solution
The battery module incorporates an acquiring wire harness with fixing members and locating rings to constrain the wire harness, reducing stress at bends and preventing cell scattering, while also using an integrated acquiring plate to simplify the acquisition of voltage and temperature parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are bent at right angles in the battery module, then wiring connections can be established, but high bending stress causes operating difficulty and cells are easy to reset after bending
Solution Approach 1:
The wire harness is pre-bent into the required shape during manufacturing, and fixing members are pre-installed at the bent positions. This preliminary preparation eliminates the need for difficult on-site bending operations and ensures proper cell positioning before the module is put into service.
Solution Approach 2:
Fixing members are introduced as intermediary components between the wire harness and the battery cells. These fixing members bear the bending stress and provide stable positioning, mediating between the wiring requirement and the operational ease requirement by preventing direct stress on the cells during operation.
2Volume of moving object
If battery cells are closely arranged in the battery module, then space utilization is improved, but limited wiring space increases operating difficulty
Solution Approach 1:
The battery module is segmented into distinct functional zones: cell arrangement zones for maximum space utilization, and separate wiring channels with adequate space for wire harness routing. This segmentation allows dense cell packing while preserving sufficient wiring space for easy installation and maintenance operations.
3Reliability
If fixing members are added to the acquiring wire harness, then stress at bends is eliminated and cells are fixed, but device complexity increases
Solution Approach 1:
Fixing members are applied locally only at the bent positions of the wire harness where stress concentration occurs, rather than throughout the entire structure. This localized application provides necessary stress relief and cell fixation while minimizing the addition of components and maintaining overall structural simplicity.
Data Source
AI summary
A battery module is disclosed, including an acquiring wire harness, a plurality of fixing members, and a plurality of locating rings. The plurality of fixing members are respectively provided at a plurality of overturning bends of the acquiring wire harness, and the fixing members are used to fix the acquiring wire harness at the overturning bends. The plurality of locating rings are arranged on the acquiring wire harness at intervals along a length direction of the acquiring wire harness. Applying the disclosure of the above embodiments, by providing locating rings on the acquiring wire harness to constrain the acquiring wire harness, can prevent battery cells from being scattered to affect the safety and aesthetics during transportation or operation.