Battery Pack HV Distribution Layout With Integrated Wire Harness
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Solution Overview
Problem
Conventional high-voltage distribution boxes in battery packs have a large volume, numerous components, and disordered wire harnesses, leading to increased production processes and manufacturing costs due to multiple wire harness connections.
Innovation Solution
A battery pack design incorporating a high-voltage distribution box with an integrated wire harness and a battery management system positioned on the same side, connected via integrated wire harnesses, reducing unnecessary winding and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate wire harnesses are used for connections in the high-voltage distribution box, then each connection can be made individually, but the wire harnesses become disordered and manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple separate wire harnesses into a single integrated wire harness assembly. This consolidation combines multiple connection functions into one unified component, eliminating the disorder caused by multiple separate harnesses while simplifying the manufacturing process by reducing the number of individual assembly steps.
2Reliability
If multiple wire harness connections are made inside the high-voltage distribution box, then all necessary connections can be established, but production processes increase and manufacturing costs increase
Solution Approach 1:
By merging multiple wire harness connections into a single integrated wire harness, the patent maintains all necessary electrical connections for reliable operation while significantly reducing the number of production steps. The integrated design allows for faster assembly and reduced manufacturing time, thereby improving productivity without compromising connection reliability.
3Reliability
If multiple wire harness connections are made inside the high-voltage distribution box, then all necessary connections can be established, but manufacturing costs increase
Solution Approach 1:
The integration of multiple wire harnesses into one unified assembly reduces manufacturing costs by minimizing the number of components that need to be sourced, managed, and assembled. The single integrated wire harness reduces material waste, simplifies inventory management, and lowers assembly labor costs while maintaining all necessary electrical connections for reliable system operation.
4Reliability
If the battery management system and high-voltage distribution box are positioned separately, then functional separation is achieved, but wire harness winding increases and assembly efficiency decreases
Solution Approach 1:
The patent positions the battery management system and high-voltage distribution box on the same side of the battery pack, utilizing lateral spatial arrangement rather than vertical separation. This dimensional repositioning reduces the distance and complexity of wire harness routing while maintaining functional separation, thereby improving assembly efficiency without compromising system reliability.
Data Source
AI summary
The application discloses a battery pack and electrical apparatus. The battery pack includes a box body, a battery module, a battery management system, a high-voltage distribution box, and a sensor located inside the box body. The high-voltage distribution box includes a high-voltage distribution box body and an integrated wire harness. A plurality of wire harnesses are integrated in the integrated wire harness, and the wire harnesses extend from the high-voltage distribution box body in a direction toward the battery management system. The battery management system is connected to the battery module, the high-voltage distribution box, the sensor, and a port of the box body through the wire harnesses.