Battery Pack BMS Assembly Insertion Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity and cost of manufacturing battery packs with multiple modules, along with safety and operational inefficiencies due to overvoltage, overcurrent, or overheating issues, are exacerbated by the difficulty in separating and mounting the battery management system (BMS) within the pack.
Innovation Solution
A battery pack design where the BMS assembly is mounted in an inner cartridge from outside the pack, allowing for easy separation and mounting without disassembling other components, featuring a hexahedral case structure with detachable plates and a rail system for secure insertion, and a circuit breaker for safety control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the BMS is mounted inside the battery pack case together with unit modules, then the battery pack structure is compact, but the BMS cannot be easily separated for maintenance and the manufacturing process becomes complicated
Solution Approach 1:
The battery pack is divided into distinct functional modules: the battery module containing unit cells, the inner cartridge holding the battery module, and the separately mountable BMS assembly. This segmentation allows the BMS to be independently installed and removed without affecting the battery module structure, resolving the contradiction between compact integration and ease of maintenance.
Solution Approach 2:
The BMS assembly is extracted from the traditional integrated mounting position inside the battery pack case and repositioned to be mounted on the outer surface of the inner cartridge. This extraction enables the BMS to be easily accessible for separation and mounting operations while maintaining a clean and organized battery pack structure.
2Quantity of substance
If multiple battery modules are used to increase capacity, then the battery pack provides required output and capacity, but the assembly process becomes very complicated requiring multiple bus bars and power cables
Solution Approach 1:
Multiple unit cells are combined into standardized battery modules, which are then electrically connected in parallel within the inner cartridge. This merging approach reduces the number of individual connection components needed compared to connecting each unit cell separately, simplifying the manufacturing process while achieving the required battery pack capacity.
Solution Approach 2:
The inner cartridge serves as a universal mounting structure that can accommodate different configurations of battery modules. The standardized interface and modular design allow the same inner cartridge structure to be used across different battery pack capacities, reducing manufacturing complexity.
3Quantity of substance
If the battery pack structure is fixed to provide required capacity, then the battery pack meets performance requirements, but it becomes difficult to modify or extend the battery pack
Solution Approach 1:
The battery pack adopts a dynamic modular architecture where the inner cartridge can be easily removed and replaced with different battery module configurations. This dynamic design allows the battery pack capacity to be adjusted or extended by simply swapping the inner cartridge assembly, providing versatility without compromising the structural integrity or performance requirements.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed herein is a battery pack configured to have a structure including at least one battery module having a structure in which a plurality of unit cells or a plurality of unit modules, each of which includes a plurality of unit cells, is electrically connected to each other, a battery pack case in which the battery module is received, an inner cartridge for fixing the battery module in the battery pack case, and a battery management system (BMS) assembly including a BMS circuit board for monitoring and controlling operation of the battery pack and a BMS case in which the a BMS circuit board is mounted, the BMS assembly being mounted in the inner cartridge from outside the battery pack in an inserting fashion.