Battery Module Sampling Wire Routing via Segmented Trough
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Solution Overview
Problem
In electric vehicle battery packs, the desultory arrangement and crossing of sampling wires lead to a high risk of short circuits and complicate maintenance due to the fixed wire bundles in limited spaces.
Innovation Solution
A battery module with an external wiring trough for orderly arrangement of sampling wires, featuring slots and lead-out grooves to prevent short circuits and simplify installation, reducing wire quantity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sampling wires are fixed in the form of wire bundles, then the battery pack can be assembled, but the wires become desultorily arranged and cross each other, increasing the risk of short circuits
Solution Approach 1:
The wire bundle is segmented into individual sampling wires, each routed through separate grooves in the wiring trough. This segmentation prevents the wires from crossing and becoming desultorily arranged, while the structured routing through grooves maintains assembly feasibility.
Solution Approach 2:
A wiring trough is introduced as an intermediary structure to contain and organize the sampling wires. The trough with its integrated grooves acts as a mediator that guides wire placement, preventing short circuits while maintaining ease of assembly through a standardized routing path.
2Ease of repair
If wire bundles are used for sampling wires, then assembly is possible, but maintenance becomes difficult due to desultory arrangement
Solution Approach 1:
By separating individual sampling wires into distinct grooves within the wiring trough, each wire becomes independently accessible and traceable. This segmentation simplifies maintenance operations compared to tangled wire bundles, while the integrated trough structure keeps the overall device complexity manageable.
Solution Approach 2:
The wiring trough with pre-formed grooves is prepared in advance during battery pack assembly, establishing an organized wire routing path before maintenance operations are needed. This preliminary organization of wires makes future maintenance significantly easier without requiring complex reconfiguration.
3Reliability
If more sampling wires are arranged in limited space, then voltage detection coverage improves, but the risk of short circuits increases
Solution Approach 1:
Multiple sampling wires for voltage detection of different battery cells are segmented into separate grooves within the wiring trough. This allows comprehensive voltage monitoring coverage while physically isolating each wire to prevent short circuits, even in limited space.
Solution Approach 2:
The wiring trough utilizes three-dimensional space by incorporating grooves at different levels and orientations. This dimensional approach allows multiple sampling wires to be routed separately without crossing, enabling comprehensive voltage detection while preventing short circuits in compact battery pack configurations.
Data Source
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AI summary
A battery module comprises a battery pack including a plurality of cells (1) and a plurality of connectors (2) for electrically connecting adjacent cells respectively; a case (3) housing the battery pack; and a sampling unit fixed to the case and including : a BIC (battery information collection) module (4) fixed onto the case; a wiring trough (6) fixed onto the case; a signal sampling terminal (7); and a sampling wire disposed within the wiring trough (6) and having a first end electrically connected to the BIC module (4) and a second end electrically connected to the signal sampling terminal (7).