Battery Pack Connector Pin Length Variation for Reliable Connection
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Solution Overview
Problem
High-power battery packs used in hybrid electric vehicles face challenges in managing and connecting multiple battery cells effectively, leading to potential failures in the protective circuit module and power relay assembly, which can affect the stability and reliability of the battery pack.
Innovation Solution
The battery pack design features connector pins of varying lengths to ensure proper connection to a protective circuit module, including a monitoring portion with B+ and B− high current lines and monitoring lines, where the lengths of the connector pins are tailored to the specifications of an analog front-end integrated circuit (AFE IC), reducing the likelihood of module failures and improving stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connector pins are formed with different lengths to ensure proper connection sequence, then connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The connector pins are designed with different lengths, creating an asymmetric structure where each pin has a specific length corresponding to its connection sequence requirement. This asymmetric design ensures that pins connect to the protective circuit module in the correct order, with longer pins making contact first and shorter pins making contact last, thereby guaranteeing proper connection reliability.
Solution Approach 2:
Each connector pin is given a specific local quality in terms of length to fulfill its particular function in the connection sequence. The varying lengths are precisely controlled to match the requirements of different connection points on the protective circuit module, ensuring that each pin performs its designated connection task effectively.
2Power
If multiple battery cells are connected in series to increase power capacity, then power output is improved, but system complexity increases
Solution Approach 1:
The battery pack is segmented into multiple battery cells connected in series, with each cell being a separate, manageable unit. The connector is also segmented into multiple pins of different lengths, with each pin responsible for connecting to a specific battery cell or monitoring point. This segmentation allows for systematic management of the complex multi-cell system.
Solution Approach 2:
The connector design with varying pin lengths serves multiple functions simultaneously: it establishes electrical connections between battery cells, provides monitoring capabilities through dedicated monitoring pins, and ensures proper connection sequencing. This multi-functional connector reduces the need for separate components for each function.
3Measurement precision
If monitoring portion includes multiple lines for each battery cell, then monitoring accuracy is improved, but connection complexity increases
Solution Approach 1:
The monitoring portion is segmented into multiple separate lines, with each line dedicated to monitoring a specific battery cell or parameter. This segmentation allows for precise individual monitoring of each cell's voltage, temperature, or other parameters, improving overall monitoring accuracy while maintaining organized connection pathways.
Data Source
AI summary
A battery pack is disclosed. In one aspect, the battery pack includes a plurality of battery cells and a monitoring portion including a plurality of lines respectively electrically connected to the battery cells. The lines include a positive current line, a negative current line, and at least one monitoring line. The battery pack further includes a connector including a plurality of connector pins formed therein, wherein the connector pins are respectively electrically connected to the lines of the monitoring portion, and a protective circuit module accommodating the connector therein. The connector pins have different lengths.