Battery Sub-Pack Assembly With Wire-Bonded BMS Coupling
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Solution Overview
Problem
Existing battery packs face challenges in efficiently coupling multiple unit modules and battery management systems (BMS) for cost-effective and convenient electrical/mechanical connections, leading to inefficiencies in component management and cost reduction.
Innovation Solution
A sub pack structure is designed with a battery module assembly and BMS assembly, featuring side beams, sensing terminals, and wire bonding for electrical connections, allowing convenient coupling of unit modules and BMS, and a battery pack configuration with serial and parallel bus bars for efficient expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple battery cells are connected in series/parallel to form a battery pack, then the output voltage and charge/discharge capacity can be adjusted according to requirements, but the complexity of electrical connections and component management increases
Solution Approach 1:
The battery pack is divided into multiple battery modules, each module containing a specific number of battery cells connected in series. This segmentation allows flexible configuration of voltage and capacity by selecting and combining different modules, while simplifying the overall electrical connection structure through standardized module interfaces.
Solution Approach 2:
The battery management system is designed with universal communication protocols and standardized connection interfaces that can manage multiple battery modules with different configurations. The BMS can adapt to various series/parallel arrangements through a unified management architecture, reducing the complexity of component management across different pack configurations.
2Ease of manufacture
If a battery module structure is used as a base for battery pack configuration, then assembly is simplified, but the electrical connection efficiency and management convenience between unit modules and BMS needs improvement
Solution Approach 1:
The battery management system adopts a nested hierarchical structure where a central BMS manages multiple battery modules, each module having its own integrated management circuit. This nested architecture allows the central BMS to communicate with individual modules through standardized interfaces, improving electrical connection efficiency while maintaining assembly simplicity through modular design.
Solution Approach 2:
Communication buses and standardized connection interfaces serve as intermediaries between the BMS and battery modules. These intermediaries enable efficient electrical connections and data exchange without requiring complex direct wiring between each component, thus improving ease of operation while preserving the simplified modular assembly structure.
Data Source
AI summary
Disclosed herein is a sub pack. The sub pack may include a battery module assembly having a plurality of unit modules and a BMS assembly. The battery module assembly may include a side beam. The BMS assembly may be electrically connected to the battery module assembly by wire bonding and include a plurality of sensing terminals at an upper portion thereof. The plurality of sensing terminals may be wire-bonded to the battery module assembly through a connecting wire.