Battery Wiring Module Cover Hinge Wire Catch Prevention
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Solution Overview
Problem
Existing battery wiring modules for vehicles risk electrical wires getting caught in the hinge mechanism when the cover is rotated to the closing position, due to the wires bending and running on the side wall portions.
Innovation Solution
The design includes a housing with a protruding portion and guiding portion adjacent to the cover facing surface, which prevents the electrical wire from running on the cover facing surface and guides it back into the housing when the cover is rotated, using an inclined surface to facilitate easy retraction and avoid catching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cover portion is made rotatable to enable opening and closing for wire installation, then the ease of operation is improved, but the electrical wire may get caught in the hinge portion during rotation
Solution Approach 1:
A guide portion is introduced as an intermediary structure between the electrical wire and the hinge portion. This guide portion redirects the wire's path during cover rotation, preventing direct contact between the wire and the hinge mechanism, thus eliminating the risk of the wire getting caught while preserving the rotatable cover's operational ease
Solution Approach 2:
The guide portion is pre-configured in the housing to establish a predetermined safe path for the electrical wire before the cover rotation begins. This preliminary arrangement ensures that as the cover rotates, the wire naturally follows the guided path and avoids the hinge portion, preventing the catching issue before it can occur
2Reliability
If the cover portion is extended to cover the upper opening completely, then the protection of the electrical wire is improved, but the wire may be pinched between the cover and the housing side wall
Solution Approach 1:
The guide portion acts as an intermediary structure that positions the electrical wire at a safe distance from the housing side wall. By redirecting the wire along the guide portion's surface, it prevents the wire from being pinched between the extended cover and the housing, while still allowing the cover to provide complete protection over the upper opening
3Ease of operation
If the electrical wire housing portion is formed with side wall portions to contain the wire, then the wire management is improved, but the wire may run on the side wall portion and get caught during cover rotation
Solution Approach 1:
The guide portion serves as an intermediary structure that modifies the wire's interaction with the side wall portion. Instead of the wire running directly on the side wall where it could be caught by the hinge, the guide portion redirects the wire along a predetermined safe path, eliminating the catching risk while maintaining organized wire management within the housing
Data Source
AI summary
A battery wiring module that can keep an electrical wire from getting caught up when a cover portion is rotated and closed. In order to keep an electrical wire from sticking out from an electrical wire housing portion, a cover portion that partially covers an upper opening of the electrical wire housing portion is provided to a first side wall portion of an electrical wire housing portion with a hinge portion. The upper end of the first side wall portion is provided with a cover facing surface that faces the cover portion in a covering position in the vertical direction (a height direction Z), and a protruding portion that is adjacent to the cover facing surface and that protrudes higher than the cover facing surface.