Modular Battery Cell Stack Sensing Assembly for Length Adjustment
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Solution Overview
Problem
There is a growing need for a length-adjustable sensing assembly in battery cell stacks to accommodate varying capacities when mounted in battery housings, while maintaining efficient electrical connections and alignment with battery cells.
Innovation Solution
A sensing assembly comprising multiple busbars and sensing frames with guide protrusions, guide grooves, and seating protrusions/protrusions, allowing for adjustable length adjustment and alignment with battery cells, facilitated by removable coupling of middle sensing frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed-length sensing assembly is used, then the manufacturing process is simple, but the battery cell stack cannot accommodate varying capacities and thicknesses
Solution Approach 1:
The sensing assembly is divided into multiple detachable sensing frames (first sensing frame, second sensing frame, third sensing frame) that can be selectively assembled. Each sensing frame has a corresponding guide protrusion and guide groove structure, allowing the assembly to be configured in different lengths by selecting and combining appropriate numbers of sensing frames, thereby adapting to various battery cell capacities while maintaining manageable complexity through standardized modular components.
Solution Approach 2:
The sensing assembly transitions from a fixed-length design to a dynamically adjustable length configuration. The detachable connection between sensing frames via guide protrusions and guide grooves enables the assembly length to be changed according to the specific battery cell stack capacity requirements, making the system adaptable rather than static.
2Adaptability or versatility
If multiple detachable sensing frames are used for length adjustment, then adaptability to varying battery capacities is improved, but alignment precision and electrical connection reliability may deteriorate
Solution Approach 1:
The guide protrusion and guide groove structures serve as intermediary alignment mechanisms between adjacent sensing frames. These features guide the relative positioning of sensing frames during assembly, ensuring precise alignment of the busbars and electrical connections without requiring complex external alignment tools or procedures, thus maintaining manufacturing precision while enabling length adjustability.
3Adaptability or versatility
If sensing frames are permanently fixed together, then structural stability is high, but flexibility for capacity changes and reconfiguration is lost
Solution Approach 1:
The sensing assembly is segmented into discrete sensing frames that can be independently assembled and disassembled. The guide protrusion and guide groove structures provide standardized connection interfaces that ensure stable structural assembly when connected, while allowing easy separation and reconfiguration. This segmentation enables the system to achieve both reconfigurability for different capacities and structural stability during operation.
4Ease of operation
If a modular detachable design is implemented, then ease of assembly and disassembly is improved, but the number of components and assembly steps increases
Solution Approach 1:
The sensing frames are designed as universal modular components with standardized guide protrusion and guide groove structures. Each sensing frame can function independently or be combined with others, and the same connection mechanism is used across all frames. This universality reduces the need for specialized components for each configuration, making the assembly process simpler despite the modular nature, as the same components and procedures are repeated rather than requiring unique parts for each assembly variant.
Data Source
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AI summary
A sensing assembly includes a plurality of busbars and a plurality of sensing frames arranged along a first direction to support the plurality of busbars. The sensing frames includes a middle sensing frame and an outer sensing frame disposed on a first side of the middle sensing frame along the first direction. The middle sensing frame includes: a first peripheral surface facing toward one side in the first direction; a second peripheral surface disposed on an opposite side to the first peripheral surface and facing toward an opposite side in the first direction; a support surface connected with the second peripheral surface and facing toward one side in a second direction crossing the first direction; a guide protrusion protruding from the first peripheral surface toward the one side in the first direction; and a guide groove disposed where the support surface and the second peripheral surface are connected.