Busbar Holding Module Positioning Recess for Torque Reduction
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Solution Overview
Problem
The existing external connection busbar configurations for electricity storage element groups, particularly those with elongated busbars, face challenges in maintaining reliable connections while minimizing torque loads during bolt-fastening, which can lead to molding mold breakage and reduced manufacturing efficiency due to fine mold portions and clearance issues.
Innovation Solution
An external connection busbar holding module with a positioning portion that includes an entrance with a predetermined clearance and a clearance reduction portion to mitigate torque loads, along with fixing pawls and a nut accommodating portion, is designed to securely hold elongated busbars, reducing the need for fine mold features and enhancing operational stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a predetermined clearance is provided between the external connection busbar and the holding member to facilitate attachment and absorb product deviation, then the ease of operation is improved, but torque load is generated during bolt fastening which may damage the welded connection
Solution Approach 1:
The holding member is pre-formed with a recess that accommodates the protruding portion of the external connection busbar before bolt fastening. This preliminary geometric configuration ensures that the busbar is properly positioned and the clearance is controlled, allowing easy attachment while preventing excessive torque transmission to the welded connection during subsequent bolt tightening
Solution Approach 2:
The protruding portion of the external connection busbar acts as an intermediary element that fits into the recess of the holding member. This intermediary structure absorbs the clearance and prevents direct transmission of torque from the bolt to the welded connection, thereby maintaining both ease of attachment and connection reliability
2Device complexity
If the welded surface of the external connection busbar and the bolt-fastening portion are orthogonal to each other, then the structural design is simplified, but the positioning precision deteriorates requiring fine mold portions that are prone to breakage
Solution Approach 1:
The holding member is pre-formed with a recess that includes a bottom surface positioned at a specific distance from the protruding portion tip. This preliminary geometric configuration establishes the positioning relationship between the busbar and holding member, eliminating the need for fine mold portions while maintaining positioning precision and simplifying the structural design
Solution Approach 2:
The design changes the positioning mechanism from relying on fine mold portions to using a distance-based parameter (the distance from the bottom surface of the recess to the tip of the protruding portion). This parameter change maintains positioning precision while allowing simpler, more robust mold design that is less prone to breakage
Data Source
AI summary
An external connection busbar holding module includes: a first external connection busbar includes a bolt-fastening portion that is bent orthogonal to one end, and to which an external connection component is to be bolted, the bolt-fastening portion being provided at another end; and an external connection busbar protector that holds the first external connection busbar. The external connection busbar protector includes a positioning portion into which the bolt-fastening portion is inserted, and that positions the first external connection busbar. The positioning portion includes an entrance portion having a predetermined clearance relative to the bolt-fastening portion, and a clearance reduction portion that reduces the predetermined clearance.