Riveted Busbar Nut Plate Assembly for Opening Alignment
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Solution Overview
Problem
Busbar and nut plate assemblies in battery systems experience misalignment due to applied forces and torques, leading to increased electrical resistance, heat generation, and false torque readings during assembly.
Innovation Solution
A secure coupling mechanism, such as rivets, is used between the busbar and nut plate to resist applied forces and maintain alignment, ensuring the openings of the nut plate align with those of the busbar, even under external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a secure coupling mechanism (rivets) is used between busbar and nut plate, then alignment stability is improved and misalignment is reduced, but device complexity increases
Solution Approach 1:
The nut plate is permanently coupled to the busbar tab region through riveting, merging two previously separate components into a unified assembly. This permanent connection eliminates relative movement between the nut plate and busbar, ensuring opening alignment is maintained under external forces and torques during assembly operations.
2Reliability
If a permanent connection is used between nut plate and busbar, then alignment stability is improved, but ease of repair deteriorates
Solution Approach 1:
The riveting process permanently couples the nut plate to the busbar tab region before the busbar assembly is subjected to external forces during operation. This preliminary permanent connection pre-establishes alignment stability, preventing misalignment from occurring in the first place, which eliminates the need for future repairs or realignment operations.
3Manufacturing precision
If riveting is used to connect nut plate and busbar, then misalignment probability is reduced, but manufacturing complexity increases
Solution Approach 1:
The riveting process permanently couples the nut plate to the busbar tab region, merging these components into a single aligned assembly. This permanent connection ensures that the openings remain precisely aligned under external forces and torques during assembly operations, eliminating misalignment issues that would require complex adjustment mechanisms.
Data Source
AI summary
The apparatus can include a busbar and a nut plate. The busbar can include a tab region. The tab region can define one or more openings. The nut plate can be configured to couple with the tab region of the busbar. One or more openings in the nut plate can align with the one or more openings of the tab region. The nut plate can have a planar shape. At least a portion of a face of the nut plate can couple with a planar face of the tab region of the busbar.