Busbar Module Connector With Slidable Screw for Tolerance Compensation
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Solution Overview
Problem
Conventional module connectors for electric modules, such as battery modules in electric vehicles, face challenges in compensating for positional tolerances without applying excessive force, as they rely on flexible conductor sections that may exert elastic restoring forces and have limited flexibility based on length.
Innovation Solution
A module connector design featuring a busbar with a rotatable screw and screw guide, allowing for force-free positional adjustment by sliding the screw along the busbar plane, providing additional freedom through rotatability and compensating for positional tolerances without elastic deformation, regardless of the busbar's length or flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible conductor sections are used to compensate for positional tolerances, then the module connector can adapt to different relative positions, but high bending forces are required and elastic restoring forces are generated
Solution Approach 1:
The screw is made movable within the through-opening, allowing it to slide and rotate dynamically. This dynamic capability enables the screw to adapt to positional tolerances without requiring high bending forces or generating elastic restoring forces, as the screw can simply shift position within the tolerance range
Solution Approach 2:
The invention changes the parameter of screw position from fixed to variable. By allowing the screw to slide within the through-opening along directions parallel to the busbar plane, the system can adjust to different relative positions of connected modules without requiring flexible conductor sections
2Adaptability or versatility
If flexible conductor sections are used to compensate for positional tolerances, then adaptability is improved, but the length of the flexible section limits the compensable position tolerance
Solution Approach 1:
The screw's ability to slide and rotate within defined boundaries provides adaptability without being constrained by the length of a flexible conductor section. The movable screw can compensate for positional tolerances through its range of motion rather than through the length of a flexible element
Solution Approach 2:
The invention extracts the flexibility requirement from the conductor section and transfers it to the screw mechanism. This eliminates the need for long flexible conductor sections, as the screw's sliding and rotating capabilities provide the necessary adaptability
3Strength
If a rigid busbar is used, then structural strength is improved, but the ability to compensate for positional tolerances is reduced
Solution Approach 1:
The system is segmented into a rigid busbar and a movable screw component. The busbar maintains its rigid structure for strength, while the screw provides the necessary adaptability through its ability to slide and rotate within the through-opening
Solution Approach 2:
The screw is designed as a dynamic element that can slide and rotate within the rigid busbar structure. This allows the rigid busbar to maintain its strength while the movable screw compensates for positional tolerances
Data Source
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AI summary
The present invention relates to a module connector (1) for electrically connecting two electric modules (10), wherein the module connector (1) comprises a busbar (4), at least one screw (26) rotatable relative to the busbar (4) and at least one screw guide (38) rotatable relative to the busbar (4), wherein the busbar (4) comprises at least one flat face (6), which defines a busbar plane (8), and at least one section of the busbar (4) comprises a through opening (16) extending perpendicularly to the busbar plane (8) through the busbar (4), wherein the at least one screw guide (38) is held at least sectionally in the through opening (16) and has a hole (40) extending parallel to the through opening (16), in which the at least one screw (26) is held at least sectionally, and wherein the at least one screw (26) is held in the through opening (16) slidably parallel to the busbar plane (8). Owing to the slidability of the screw, certain positional tolerances can be compensated in a force-free manner upon connecting the electric modules (10). Further, the invention relates to a connection assembly (2) with such a module connector (1).