Battery Sampling Assembly for Welded Pole Connections
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Solution Overview
Problem
The existing battery module sampling methods are complex and inefficient, particularly when battery cells have end surfaces with welded poles, as they require multiple assembly steps and can't perform voltage sampling due to limited space, leading to reduced production efficiency and increased assembly difficulty.
Innovation Solution
A battery sampling device with a conductive component and sampling component that are electrically connected via a bearing component, allowing for a weld-free installation by inserting the bearing component between battery cells with welded poles, ensuring reliable and automatic connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sampling component is welded to the connecting strips, then the sampling connection is reliable, but the assembly steps increase and production efficiency decreases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion system. The bearing component is inserted into the gap between battery cells and provides mechanical contact through conductive components, eliminating the need for welding operations while maintaining electrical connection reliability.
Solution Approach 2:
The bearing component serves as an intermediary element between the battery cells and the sampling component. It provides a mechanical interface that enables electrical connection without direct welding, simplifying the assembly process while ensuring reliable sampling.
2Reliability
If the sampling component is welded to the connecting strips, then the electric connection is reliable, but the assembly difficulty increases
Solution Approach 1:
The patent replaces the welding process with a simple mechanical insertion operation. The bearing component is designed to be inserted into the gap between battery cells, providing electrical connection through conductive components without requiring welding equipment or skilled welding operations.
Solution Approach 2:
The bearing component is designed to automatically establish electrical connection upon insertion into the gap between battery cells. The conductive components within the bearing component make contact with the battery cell poles, creating the sampling circuit without requiring additional assembly steps or external assistance.
3Adaptability or versatility
If transfer welding and sampling are performed, then the sampling function is achieved, but the structure becomes complicated and manufacturing becomes difficult
Solution Approach 1:
The patent combines the bearing function and the electrical sampling function into a single integrated component. The bearing component simultaneously provides mechanical support and establishes electrical connection through its conductive components, eliminating the need for separate welding and sampling operations.
Solution Approach 2:
The bearing component is designed to perform multiple functions: it provides mechanical bearing support, establishes electrical connection for sampling, and fits into the gap between battery cells. This multi-functional design simplifies the overall structure while achieving the sampling function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the assembly process, enhances reliability by preventing disconnection during vibration, and allows for efficient sampling of electrical parameters without the need for welding, addressing the limitations of existing methods in battery modules with butt welded poles.
Implementation Method 1
the conductive component has a certain deformation displacement characteristic to be further adapted to the dimension of the battery after cyclic expansion
Implementation Method 2
a conductive component in contact with the pole and electrically connected to the pole
Data Source
AI summary
A battery sampling device, a battery, and an electricity consumption device are provided. The battery sampling device includes a conductive component, a sampling component and a bearing component. The conductive component is in contact with a pole and is electrically connected to the pole. The sampling component is electrically connected to the conductive component and is configured to transmit or process electrical parameters acquired by the conductive component. The bearing component is configured to bear the conductive component and the sampling component and to be adapted to being inserted into a gap between two battery cells with end surfaces of the pole welded with each other. The conductive component abuts against a side surface of the pole and the sampling component, so as to realize an electric connection among the pole, the conductive component and the sampling component.