Busbar Module Routing Groove Design for Compact Wire Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing busbar modules require complex bending operations for electric wire routing, increasing time and effort, and result in a larger module size due to the placement of electric wire connection ends between busbar and routing groove portions.
Innovation Solution
A busbar module design featuring a case with integrated busbar accommodation rows and electric wire routing grooves, where the connection end of the electric wire is accommodated in a concave-shaped portion with a cover that forms a routing path, allowing wires to be routed from the second end to the first end, reducing the need for bending and minimizing module width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electric wire connection end is accommodated in a separate portion between the busbar accommodation portion and the electric wire routing groove portion, then the electric wire routing can be performed, but the width dimension of the busbar module is increased
Solution Approach 1:
The invention merges the connection end accommodation portion with the electric wire routing groove portion by providing the connection end accommodation portion at one end of the routing groove portion. This integration eliminates the need for a separate accommodation portion between the busbar accommodation portion and routing groove, thereby reducing the width dimension while still allowing proper electric wire routing and connection end accommodation.
2Ease of operation
If a complicated bending operation is required to guide the electric wire into the routing groove portion, then the electric wire can be routed, but the routing operation takes more time and effort
Solution Approach 1:
The invention provides a lead-out portion that extends from the busbar accommodation portion toward the electric wire routing groove portion, with a connection end accommodation portion positioned at the end of the routing groove. This preliminary structural arrangement guides the electric wire connection end directly to the appropriate location, eliminating the need for complicated bending operations and significantly reducing routing operation time and effort.
3Reliability
If the electric wire on the downstream is disposed to avoid interfering with the connection end of the electric wire on the upstream, then proper electrical connection is maintained, but the module width is increased
Solution Approach 1:
The invention utilizes the longitudinal dimension of the routing groove portion to accommodate multiple electric wires in sequence, with the connection end accommodation portion positioned at one end. This allows downstream electric wires to be routed without interfering with upstream connection ends, while maintaining compact width dimensions by efficiently utilizing the length of the routing groove rather than expanding the width.
Data Source
AI summary
A busbar module includes a case to be attached to a battery assembly, busbars and electric wires having a connection end to be connected to the busbars. The case includes busbar accommodation portions to accommodate the busbars and an electric wire routing groove portion to accommodate the electric wires. The electric wire routing groove portion includes a connection end accommodation portion to accommodate the connection end, an accommodation portion cover and an electric wire lead-out portion configured such that the electric wires are drawn out from the connection end accommodation portion toward a direction. An outer surface of the accommodation portion cover is to form a bottom surface of a routing path configured such that the electric wires drawn out from the connection end accommodation portion extend in the routing path.