Busbar Module Plate Connector Design for Electric Wire Protection
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Solution Overview
Problem
The existing busbar modules for electric vehicles and hybrid vehicles require multiple molds for production, increasing costs and risking damage to electric wires during handling due to the need for separate molds for plates with and without electric wire fixing portions.
Innovation Solution
A busbar module design featuring a connector system with a second connecting piece and a first connecting piece, including a projecting portion and erected wall portions, which allows plates to be connected without applying load to electric wires and can be molded using a single mold, using a binding band to secure wires and prevent movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate molds are used for plates with and without electric wire fixing portions, then electric wires can be fixed securely, but production costs increase due to multiple molds
Solution Approach 1:
The plate is designed with a universal structure that can accommodate both electric wire fixing portions and connection portions for connecting to other plates. The connection portion includes a connection protrusion that engages with a connection recess, allowing the plate to serve dual functions: securing electric wires through the fixing portion and connecting to adjacent plates through the connection portion. This eliminates the need for separate molds for different plate types.
2Ease of operation
If electric wires are arranged from one plate to another for connecting plates, then plates can be connected, but electric wires are pulled and detached from terminals during handling
Solution Approach 1:
The plate structure is segmented into distinct functional portions: an electric wire fixing portion that secures wires, and a connection portion that connects to other plates. The connection portion includes a connection protrusion and connection recess that enable plate-to-plate connection without involving the electric wires. This segmentation ensures that electric wires remain isolated and undisturbed during plate handling and connection operations.
3Ease of operation
If electric wires are used to connect plates together, then plates can be joined, but wires are subjected to load and risk damage during carrying
Solution Approach 1:
The connection function is extracted from the electric wires and assigned to a dedicated connection portion on the plate. The connection portion includes a connection protrusion and connection recess that enable mechanical coupling between plates. By extracting the connection function from the electric wires, the wires are no longer subjected to mechanical loads during plate handling and carrying, preserving their electrical integrity and preventing damage.
Data Source
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AI summary
In a busbar module for connecting a plurality of batteries of a battery unit, the batteries are arranged so that electrodes of each of the batteries having different polarities are disposed adjacent to each other. The busbar module includes a plurality of busbars, a plurality of terminals, a plurality of wires, a plurality of plates and a connector. The busbars connect the electrodes adjacent to each other. The terminals are connected to the busbars respectively to detect a voltage of the batteries. The wires are connected to the terminals respectively. The plates accommodate the busbar, the terminals and the wires, and provided above the battery unit. The connector connects the plates together.