Battery Module Cable Coiling and Routing Mechanism
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Solution Overview
Problem
The complexity and error-proneness of producing battery packs for hybrid and electric vehicles due to the need for variously sized cables for connecting battery modules and control devices, which restricts positioning options and increases manufacturing complexity.
Innovation Solution
A battery module design with integrated cable guides and a coiling device on the cover for securing cables, ensuring consistent cable lengths and allowing for flush-mounting, reducing the need for multiple cable lengths and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cables of different lengths are used to connect battery modules and control devices, then the positioning options for control devices and battery modules are flexible, but the manufacturing complexity increases and the process becomes error-prone
Solution Approach 1:
The cable management system is segmented into fixed cable guides integrated into the battery module housing and a separate coiling device. This segmentation allows cables to be routed through fixed paths while the coiling device handles length variation, simplifying manufacturing by standardizing the cable guide positions while maintaining flexibility in cable length accommodation.
Solution Approach 2:
The coiling device acts as an intermediary between the fixed cable guides and the variable-length cables. It mediates the contradiction by providing a mechanism that accepts cables of different lengths while maintaining consistent routing through the fixed guides, thus preserving positioning flexibility without increasing manufacturing complexity.
2Ease of manufacture
If cables are routed externally on battery housing, then cable routing is simplified, but cables are exposed to damage and positioning is restricted
Solution Approach 1:
The cable routing system uses a nested structure where cable guides are integrated into the battery module housing, and the coiling device is positioned within or on the housing. This nesting protects cables from external damage while maintaining simplified routing, as cables remain enclosed within the housing structure rather than being exposed externally.
Solution Approach 2:
The cable routing transitions from external two-dimensional routing to internal three-dimensional routing through integrated guides and coiling mechanisms. This dimensional change allows cables to be protected within the housing volume while maintaining routing simplicity through predetermined guide paths.
3Adaptability or versatility
If multiple cables of different lengths are prepared for production, then all connection scenarios can be covered, but inventory complexity and error potential increase
Solution Approach 1:
The coiling device provides a universal solution that can accommodate cables of any length through its coiling mechanism. Instead of requiring multiple specialized cables for different connection scenarios, a single universal coiling device can handle all cable length requirements, reducing inventory complexity while maintaining adaptability to various connection scenarios.
Solution Approach 2:
The system changes the parameter of cable length from a fixed, discrete set of values to a continuous variable that can be adjusted by the coiling device. This parameter change allows a single cable type to serve multiple connection scenarios by varying the amount of cable coiled, eliminating the need for multiple predefined cable lengths.
4Volume of moving object
If battery modules are flush-mounted, then space utilization is optimized, but cable access and routing become more difficult
Solution Approach 1:
Cable guides are preliminarily integrated into the battery module housing during manufacturing, with openings or access points positioned to facilitate cable routing even in flush-mounted configurations. This preliminary action ensures that cable access is maintained while achieving optimized space utilization through flush mounting.
Solution Approach 2:
The coiling device serves as an intermediary that bridges the contradiction between flush-mounted compactness and cable accessibility. It provides a mechanism for cable access that does not require protruding structures, allowing flush mounting while maintaining ease of cable operation through its integrated design.
Data Source
AI summary
A battery module comprising a plurality or a multiplicity of battery cells which are positioned in a battery module housing, wherein the battery module housing comprises side walls (12), a base surface and a battery module cover (14), wherein the battery module cover (14) comprises at least one terminal (16) for the current-carrying or data-conducting contacting of the battery module (10), wherein the terminal (16) is provided with a current-carrying or data-conducting cable (26), and wherein the battery module cover (14) comprises a device (28) for the coiling of said current-carrying or data-conducting cable (26).