Battery Busbar-Tote Alignment for Faster Module Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of busbars with a tote in a battery assembly for electric vehicles is complex and time-consuming, requiring efficient alignment features to improve manufacturing efficiency and reliability.
Innovation Solution
The use of physical alignment features such as pins and receptacles, along with integrated pierce nuts, clips for cable restraint, and brackets for board or wire support, facilitates the efficient integration of busbars with the tote, enhancing electrical isolation and alignment within the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional integration methods are used to integrate busbars with a tote in a battery assembly, then the integration can be completed, but the process becomes complicated and time-consuming
Solution Approach 1:
The busbar is designed with self-aligning features including protrusions that fit into recesses on the tote, and integrated pierce nuts that automatically align with mounting holes. This self-service alignment mechanism eliminates the need for complex external alignment tools or procedures, thereby simplifying the integration process and reducing assembly time while maintaining precision.
Solution Approach 2:
Multiple functions are merged into the busbar structure: electrical connection, mechanical support, alignment reference, and cable mounting are all integrated into single components. The pierce nuts are integrated directly into the busbar, and alignment protrusions are formed as part of the busbar structure, reducing the number of separate parts and simplifying the overall integration process.
2Ease of manufacture
If alignment features are added to improve integration efficiency, then manufacturing efficiency improves, but the device complexity increases
Solution Approach 1:
The alignment system is segmented into discrete, simple geometric features: cylindrical protrusions on the busbar correspond to recesses in the tote, and pierce nuts are positioned at specific locations. This segmentation into simple, standardized features makes the alignment process efficient while keeping each individual feature simple in design and easy to manufacture.
Solution Approach 2:
The alignment protrusions and recesses serve multiple functions: they provide precise positional alignment, define orientation, and act as mechanical locators during assembly. The pierce nuts simultaneously provide electrical connection, mechanical fastening, and alignment reference. This multi-functionality reduces the need for separate alignment components, thereby improving manufacturing efficiency without proportionally increasing structural complexity.
Data Source
AI summary
A battery system having busbars integrated with a tote is provided. The battery system can include a first pin located on a busbar or a tote and a first receptacle on the busbar or the tote. The first receptacle can include a first opening having a first size in a first direction that is greater than or equal to a first size of the first opening in a second direction. A second pin and a second receptacle can be located on the busbar or the tote. The second receptacle can include a second opening having a second size in the first direction that is less than or equal to a second size of the second opening in the second direction to align the busbar with the tote via the first pin inserted into the first receptacle and the second pin inserted into the second receptacle.