Battery Wiring Module Resin Protector Wire Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In battery modules for electric or hybrid vehicles, detection wires connected to terminals can be displaced when pulled, making reliable electrical connection challenging due to manufacturing and assembling tolerances.
Innovation Solution
A battery wiring module design featuring a resin protector with a terminal accommodating portion, a wire accommodation groove, and through grooves that allow the detection wire to be bent at multiple positions, preventing displacement by routing and holding the wire in a bent state within the protector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the detection wire is pulled from outside with strong force, then the detection terminal may be displaced, but this makes it difficult to connect to the electrode terminal due to displacement
Solution Approach 1:
The detection wire is bent into a curved configuration within the resin protector, creating a zigzag or U-shaped routing path. This curvature allows the wire to absorb pulling forces through elastic deformation of the bent sections rather than transmitting the force directly to the terminal connection, thereby maintaining connection stability while accommodating external pulls
Solution Approach 2:
The detection wire is nested within the resin protector housing, with the wire routing channel providing a constrained path that guides and secures the wire. The resin protector acts as a protective enclosure that holds the bent wire in place and prevents displacement of the terminal connections during assembly and operation
2Stability of the object's composition
If the detection wire is bent at multiple positions to prevent displacement, then wire movement is suppressed, but this increases the complexity of wire routing
Solution Approach 1:
The wire routing channel is integrated directly into the resin protector structure, combining the functions of wire guidance, bending, and protection into a single molded component. This eliminates the need for separate routing channels or additional fastening elements, reducing overall assembly complexity while maintaining effective wire positioning
Solution Approach 2:
The resin protector is designed with specific geometric parameters including the shape, depth, and curvature of the wire routing channel. By optimizing these dimensional parameters during the molding design phase, the wire naturally follows the desired bent path without requiring complex external constraints or multiple adjustment steps
3Ease of manufacture
If the terminal is held movably in the terminal accommodating portion, then manufacturing and assembling tolerances can be absorbed, but this may reduce connection precision
Solution Approach 1:
The terminal is designed with movable capability within the terminal accommodating portion, allowing dynamic adjustment during assembly to accommodate manufacturing tolerances. The terminal can shift position within defined limits to achieve proper alignment with the electrode terminal, ensuring reliable connection despite variations in manufacturing dimensions
Data Source
AI summary
A battery wiring module to be mounted on a unit cell group formed by arranging a plurality of unit cells including positive and negative electrode terminals includes a terminal to be electrically connected to the electrode terminal, a detection wire for detecting a state of the unit cell by being electrically connected to the terminal, and a resin protector including a terminal accommodating portion for accommodating the terminal, a wire accommodation groove for accommodating the detection wire and a through groove allowing communication between the terminal accommodating portion and the wire accommodation groove and used to pull out the detection wire connected to the terminal into the wire accommodation groove. The detection wire is bent at least at two or more positions in the wire accommodation groove or the through groove and held in a bent state while being routed in the resin protector.