Bus Bar Module Lid Hinge Failure Prevention
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Solution Overview
Problem
Existing bus bar modules in electric vehicles and hybrid vehicles face issues where the hinge supporting the lid of the electric wire routing structure can break, causing the lid to float and allowing electric wires to penetrate into gaps, leading to potential electrical failures and safety hazards.
Innovation Solution
The bus bar module incorporates a sub-engaged portion and sub-engaging portion on the lid's support side edge, along with a protrusion wall on the inner surface of the first side wall, which restricts the lid's rotation and prevents it from floating, even if the hinge is broken, by engaging with a sub-pawl receiving portion and preventing erroneous penetration into the electric wire routing groove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thin plate-shaped hinge is used to support the lid, then the device complexity is reduced and ease of manufacture is improved, but the hinge may break during rotation causing the lid to float
Solution Approach 1:
The engagement mechanism is segmented into multiple independent components: the engaged portion on the lid, the engaging portion on the second side wall, the sub-engaged portion near the hinge, and the sub-engaging portion on the first side wall. This segmentation ensures that even if the hinge fails, the lid remains constrained by the engagement portions, preventing floating while maintaining manufacturing simplicity.
2Ease of operation
If the lid is allowed to rotate freely on the hinge, then the ease of operation is improved, but the lid may float when the hinge is broken
Solution Approach 1:
The lid engagement system transitions from a static single-point hinge connection to a dynamic multi-point engagement system. The lid can rotate freely during normal operation due to the hinge, but automatically engages with both the engaging portion and sub-engaging portion on the side walls, creating adaptive constraint that maintains reliability while preserving operational ease.
Solution Approach 2:
The sub-engaged portion and sub-engaging portion are positioned to provide preliminary constraint near the hinge area. This beforehand cushioning ensures that even if the hinge breaks during operation, the lid is already constrained by the engagement portions, preventing floating and protecting the electric wires before failure occurs.
3Object-affected harmful factors
If the lid covers the electric wire routing groove to block the groove opening, then the protection of electric wires is improved, but the lid must be securely fixed which increases device complexity
Solution Approach 1:
The engagement mechanism merges the lid's closing function with its securing function. The engaged portion and engaging portion, along with the sub-engaged and sub-engaging portions, are integrated into the lid structure itself rather than being separate fastening components. This merging provides secure fixation to protect electric wires while avoiding additional complex fastening mechanisms.
Data Source
AI summary
A bus bar module includes an electric wire routing structure that is attached to an battery assembly including a plurality of battery cells and accommodates a plurality of bus bars in which each electrodes of the battery cells is electrically connected to each other, a plurality of electric wires connected to the battery cells via the bus bars, respectively, an electric wire routing groove formed in the electric wire routing structure and accommodating the electric wires in a pair of side walls, and a lid that is supported by a first side wall via a hinge and covers the electric wire routing groove to block a groove opening.