Hinge Cover Lifting Prevention in Busbar Wire Routing
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Solution Overview
Problem
In vehicular assembled batteries, the busbar module's hinge cover can be lifted during wire routing, causing detection lines to jump out of the wire routing groove, leading to unreliable connections and potential electrical issues.
Innovation Solution
A wire routing structure where the hinge cover is positioned below the second wire and integrated with the case via a hinge portion, preventing the hinge cover from lifting even when the second wire is lifted, ensuring the first wires remain secured within the groove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the power line is routed to cross the wire routing groove and held by the wire holding portion on the hinge cover, then the power line can be securely fixed, but the hinge cover may be lifted up together with the wire holding portion when the power line is lifted, causing the hinge cover to open and detection lines to jump out
Solution Approach 1:
The hinge portion acts as an intermediary element between the hinge cover and the case. It is positioned below the second wire (power line) and interposes the first wire (detection line) between itself and the connection terminal. This intermediary structure allows the hinge cover to remain connected to the case even when the power line is lifted, preventing the hinge cover from opening while still allowing the power line to be held by the wire holding portion.
Solution Approach 2:
The hinge portion is positioned in a different spatial dimension (below the second wire) rather than directly above or at the same level as the wire holding portion. This dimensional arrangement creates a mechanical constraint where lifting the power line vertically does not translate to vertical movement of the hinge cover, as the hinge portion anchors it from below.
2Reliability
If the hinge cover is positioned to cover the wire routing groove, then the detection lines are protected within the groove, but the hinge cover can open when the power line is lifted, causing detection lines to jump out
Solution Approach 1:
The hinge portion serves as a mediating structure that maintains the hinge cover's connection to the case. By positioning it below the second wire and interposing the first wire between the hinge portion and connection terminal, it creates a mechanical linkage that prevents the hinge cover from opening while still allowing it to cover and protect the wire routing groove effectively.
Solution Approach 2:
The hinge portion is designed to preemptively counteract the lifting force applied to the power line. By being positioned below the second wire and connected to both the hinge cover and case, it creates a preliminary mechanical constraint that opposes any upward movement of the hinge cover before such movement can occur, thus preventing the hinge cover from opening.
3Reliability
If additional components are added to prevent hinge cover opening, then connection reliability improves, but manufacturing cost and device complexity increase
Solution Approach 1:
The hinge portion serves multiple functions: it connects the hinge cover to the case, positions itself below the second wire, interposes the first wire between itself and the connection terminal, and prevents the hinge cover from opening. By making this single component multi-functional, the patent avoids the need for additional separate components, thereby maintaining reliability while minimizing device complexity and manufacturing cost.
Solution Approach 2:
The patent merges the functions of wire routing, wire holding, and hinge cover attachment into a single integrated hinge portion structure. This consolidation eliminates the need for separate fastening components or additional structural elements, achieving reliable connection prevention while keeping the overall device simple and cost-effective.
Data Source
AI summary
A wire routing structure includes a case, a wire routing groove formed in the case, a first wire accommodated in the wire routing groove, a second wire one end of which a connection terminal is attached, and a hinge cover connected to the case via a hinge portion. The hinge cover includes a wire holding portion that holds the second wire. The hinge portion positions in an opposite side of the connection terminal while interposing the first wire between the hinge portion and the connection terminal, and positioned below the second wire.