Battery Module Bus Bar Assembly Guide
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Solution Overview
Problem
Existing battery modules face challenges in efficiently connecting multiple battery packs due to issues with output voltage and current, particularly in high-power applications like electric vehicles, where the number of battery cells increases the complexity of connections and can lead to faulty binding and increased resistance.
Innovation Solution
A battery module design that includes a bus bar system with guides for precise assembly of bus bars between battery packs, ensuring proper connection and preventing faulty binding, while also incorporating a master pack for controlling recharging and discharging operations, allowing for flexible output configurations by connecting battery packs in series or parallel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of battery cells is increased to achieve higher output voltage and current, then the power output is improved, but the complexity of connections and risk of faulty binding increases
Solution Approach 1:
The battery module is divided into multiple battery packs, each containing a specific number of battery cells. This segmentation allows the system to achieve high power output by combining multiple standardized modules rather than using a single complex configuration, thereby reducing connection complexity while maintaining high power capability.
Solution Approach 2:
Guides are pre-formed on the battery pack cases to indicate and constrain the assembly positions of bus bars. This preliminary action ensures that during assembly, the bus bars are correctly positioned without requiring complex alignment procedures, thus reducing the risk of faulty binding while maintaining high power output capabilities.
2Power
If the number of battery cells is increased to achieve higher output voltage and current, then the power output is improved, but the risk of faulty binding increases
Solution Approach 1:
Guides are pre-formed on the battery pack cases to indicate and constrain the assembly positions of bus bars. This preliminary action ensures that during assembly, the bus bars are correctly positioned without requiring complex alignment procedures, thus reducing the risk of faulty binding while maintaining high power output capabilities.
Solution Approach 2:
The guides act as intermediary elements between the battery pack cases and the bus bars. They mediate the assembly process by providing physical constraints and guidance, ensuring that the bus bars are correctly positioned and reducing the risk of faulty binding even as the number of battery cells increases.
3Ease of manufacture
If traditional binding methods are used without guides, then the manufacturing process is simpler, but faulty binding occurs and connection reliability decreases
Solution Approach 1:
Guides are pre-formed on the battery pack cases during manufacturing. This preliminary action ensures that during assembly, the bus bars are correctly positioned without requiring complex alignment procedures. The guides are simple structural features that add minimal manufacturing complexity while significantly improving connection reliability.
Solution Approach 2:
The guides on the battery pack cases provide self-aligning functionality during assembly. The bus bars naturally follow the guides to achieve correct positioning without requiring additional alignment tools or complex procedures, thus maintaining ease of manufacture while improving reliability.
4Ease of operation
If bus bars are connected without precise positioning guides, then the assembly process is more flexible, but connection precision and electrical contact quality decrease
Solution Approach 1:
The guides on the battery pack cases provide self-aligning functionality during assembly. The bus bars naturally follow the guides to achieve correct positioning without requiring additional alignment tools or complex procedures, thus maintaining ease of manufacture while improving reliability.
Solution Approach 2:
The guides act as intermediary elements between the battery pack cases and the bus bars. They mediate the assembly process by providing physical constraints and guidance, ensuring that the bus bars are correctly positioned and reducing the risk of faulty binding even as the number of battery cells increases.
Data Source
AI summary
Provided is a battery module including a bus bar and a plurality of battery packs electrically connected to each other by the bus bar, wherein each of the battery packs includes a case in which a first guide for guiding an assembly position of the bus bar is formed, and the first guide extends in a first direction around a terminal. According to one or more embodiments, there is provided a battery module including a guide for guiding an assembly position of a bus bar in a structure of binding together a plurality of battery packs using the bus bar, thereby facilitating binding the battery packs together and preventing faulty binding.