Integrated Cover for Battery Wiring Module Assembly
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Solution Overview
Problem
The conventional wiring module configuration for electric vehicles and hybrid vehicles is complex due to separate bus bar covers, increasing the number of components and making it time-consuming to close the covers during assembly.
Innovation Solution
A wiring module with bus bar and wire covers integrated into the insulating protector, allowing independent opening and closing via hinges, reducing the number of components and simplifying the structure, while maintaining efficient assembly and space savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bar covers are provided as separate members, then the wire routing grooves can be covered in advance to prevent detection wires from protruding, but the number of components increases and the structure becomes complex
Solution Approach 1:
The bus bar cover and wire cover are merged into a single integrated cover structure. The cover includes a bus bar cover portion that covers the bus bar housing portion and a wire cover portion that covers the wire routing groove, reducing the number of components from two separate covers to one integrated cover while maintaining independent protection functions for both bus bars and detection wires
2Ease of operation
If bus bar covers are provided as separate members, then independent covering is possible, but it takes time to close the covers during assembly
Solution Approach 1:
The bus bar cover and wire cover are combined into a single integrated cover that can be closed in one operation. The cover is configured with both a bus bar cover portion and a wire cover portion that are connected, allowing both covers to be closed simultaneously rather than requiring separate closing operations for each cover
Solution Approach 2:
The integrated cover is segmented into functional portions (bus bar cover portion and wire cover portion) that can independently cover their respective areas, maintaining the ability to provide targeted protection while enabling simultaneous closure as a single component
3Adaptability or versatility
If bus bar covers are provided as separate members, then independent opening and closing is possible, but the number of components increases
Solution Approach 1:
The bus bar cover and wire cover are merged into one integrated cover component. The cover includes a bus bar cover portion for covering the bus bar housing portion and a wire cover portion for covering the wire routing groove, reducing the component count from two separate covers to one while maintaining independent access capability through the hinge connection
Data Source
AI summary
An insulating protector attached to one side of a unit cell group includes: two bus bar housing portions, in each of which a plurality of bus bars for connecting adjacent electrode terminals are aligned and housed, and are respectively provided at positions near two lateral side edge portions of the insulating protector extending in a direction in which the bus bars are aligned; and two wire routing grooves that are provided on an inner side of each bus bar housing portion, and in which detection wires drawn from unit cells are routed so as to detect the state of the unit cells. A bus bar cover for covering the closer one of the bus bar housing portions and a wire cover for covering the wire routing groove on the inner side of the closer bus bar housing portion are provided on each lateral side edge portion of the insulating protector.