Battery Wiring Module Sub-Assembly Protector Routing
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Solution Overview
Problem
Conventional battery wiring modules face issues with wire tangling and incorrect routing due to the complexity of connecting coated wires to busbars, leading to decreased workability and increased risk of misrouting in electric vehicle battery assemblies.
Innovation Solution
A battery wiring module with a sub-assembly protector that holds coated wires in predetermined routing paths, improving the routing process by preventing tangling and misrouting, and allowing for accurate connection to busbars and external terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coated wires are connected to busbars and routed through the wire routing passage, then electrical connection is achieved, but wire tangling and misrouting occur reducing workability
Solution Approach 1:
The patent applies preliminary action by pre-assembling the coated wires with their connecting parts attached to the busbars before installing the entire assembly into the wire routing body. This pre-assembly ensures that wires are already positioned and connected correctly, eliminating the tangling and misrouting problems that would occur if wires were routed individually after assembly.
Solution Approach 2:
The patent merges multiple components (coated wires, connecting parts, and busbars) into a single integrated sub-assembly that is installed as one unit. By combining these elements beforehand, the patent ensures proper wire routing and connection while improving workability, as the entire wired assembly is simply placed into the wire routing body without individual wire manipulation.
2Adaptability or versatility
If multiple coated wires are routed individually, then connection flexibility is maintained, but tangling and indiscernible wiring direction occur
Solution Approach 1:
The patent segments the wire routing process into two distinct stages: (1) pre-assembly of wires with connecting parts and busbars into a organized sub-assembly, and (2) installation of the complete sub-assembly into the wire routing body. This segmentation maintains connection flexibility while reducing routing complexity by handling wires as a pre-organized unit rather than individual components.
Data Source
AI summary
A battery wiring module has a novel structure with which workability of a wire routing process can be improved and is able to prevent or reduce the occurrence of misrouting. A battery wiring module includes a plurality of busbars that electrically connect adjacent battery cells of a plurality of battery cells arranged in a row, a plurality of coated wires connected at one end to an external connection terminal and a connecting part provided at the other end being connected to one of the busbars, a wire routing body in which a busbar housing frame that houses the busbars and a wire routing passage that routes the coated wires are provided, and a sub-assembly protector that is mounted to the wire routing body, the sub-assembly protector holding a plurality of coated wires.