Bus Bar Module Hinge Configuration for Battery Assembly
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Solution Overview
Problem
The existing bus bar modules for power supply units in hybrid and electric vehicles require excessive force for assembly due to an excess number of hinges, increasing the load on operators and complicating the expansion and contraction of the electric wire routing structure to accommodate battery stack tolerance.
Innovation Solution
A bus bar module design with alternately offset groove-side and lid-side hinges allows for reduced hinge numbers, enabling easier expansion and contraction of the electric wire routing structure while maintaining structural integrity, thereby improving assembly workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If groove-side hinges are set between all pairs of adjacent electric wire routing grooves and lid-side hinges are set between some pairs of adjacent lids, then the electric wire routing structure can accommodate battery stack tolerance, but the number of hinges increases excessively, requiring more assembly force and increasing operator load
Solution Approach 1:
The patent extracts and eliminates redundant hinges from the system. Specifically, it removes groove-side hinges from non-adjacent grooves and lid-side hinges from non-adjacent lids, keeping only the minimum necessary hinges to maintain adaptability. This extraction principle directly reduces the total hinge count while preserving the essential function of accommodating battery stack tolerance.
Solution Approach 2:
The patent segments the hinge configuration into two distinct types: groove-side hinges and lid-side hinges. By alternating and offsetting these two types of hinges, the design creates a segmented pattern that maintains structural integrity with fewer total hinges. This segmentation allows the structure to be divided into movable and fixed sections, achieving adaptability without requiring hinges at every possible location.
2Adaptability or versatility
If an excess number of hinges are used in the electric wire routing structure, then the structure can accommodate battery assembly tolerance, but the force required to assemble the bus bar module increases
Solution Approach 1:
The patent extracts unnecessary hinges that contribute to assembly difficulty. By removing redundant hinges while retaining essential ones, the design reduces the total force required during assembly. The remaining hinges are strategically positioned to provide adequate tolerance accommodation without creating excessive resistance during the assembly process.
Solution Approach 2:
The patent implements a dynamic hinge configuration where groove-side and lid-side hinges alternate and offset each other. This dynamic arrangement allows the structure to flex and adapt during assembly, reducing the peak force required. The alternating pattern creates a progressive deformation mechanism that distributes assembly force more evenly, rather than requiring simultaneous force application across multiple hinges.
3Ease of operation
If groove-side hinges and lid-side hinges are alternately set and offset from each other, then the number of hinges is reduced and assembly workability is improved, but the strength of the electric wire routing structure must be maintained
Solution Approach 1:
The patent segments the hinge arrangement into alternating groove-side and lid-side hinges that offset each other. This segmented pattern reduces the total number of hinges while maintaining structural strength through strategic positioning. The segmentation creates a balanced distribution of stress points, ensuring that the structure remains strong despite having fewer hinges.
Solution Approach 2:
The patent employs an asymmetric alternating pattern where groove-side and lid-side hinges are offset from each other rather than positioned symmetrically. This asymmetric arrangement optimizes both strength and ease of operation by creating a staggered configuration that distributes loads more effectively and provides better mechanical leverage during assembly, thereby improving workability while maintaining structural integrity.
Data Source
AI summary
A bus bar module includes a plurality of bus bars in which a plurality of battery cells of a battery assembly electrically connect to each other, a plurality of electric wires electrically connected to the plurality of bus bars, and an electric wire routing structure that accommodates the plurality of electric wires. The electric wire routing structure includes a plurality of electric wire routing grooves formed in an upwardly opening gutter shape and disposed along an overlapping direction of the plurality of battery cells, and a plurality of lids connected to first side walls of the plurality of electric wire routing grooves via hinges so as to be rotatable and covering the plurality of electric wire routing grooves so as to block groove openings of the plurality of electric wire routing grooves, respectively.