Cable Extra Length Absorbing Structure for Bus Bar Modules
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Solution Overview
Problem
Existing bus bar modules for hybrid and electric vehicles lack a structure to absorb variations in cable length, leading to unintended cable deflection and potential interference with the bus bar or peripheral devices.
Innovation Solution
A cable extra length absorbing structure featuring a pair of cable clamps with axis-shifted holding portions, allowing the cable to bend in an S shape and reducing deflection width, and a hang-down preventing portion to stabilize the absorption state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable clamps are arranged coaxially without extra length absorption structure, then the structure is simple, but cable length variation causes large deflection width and potential interference
Solution Approach 1:
The patent applies asymmetry by shifting the center axes of the two cable holding portions relative to each other in the axial direction. This asymmetric arrangement creates a deflection path for the cable between the clamps, allowing the cable to absorb length variations through bending while maintaining a compact structure without requiring additional complexity
2Ease of operation
If cable clamps are disposed at predetermined intervals, then cable positioning is stable, but cable length variation generates unintended bent portions with large deflection width
Solution Approach 1:
The patent solves the deflection width problem by utilizing the axial dimension through asymmetric positioning of holding portions. Instead of allowing lateral deflection (large deflection width), the asymmetric axial arrangement guides the cable to deflect along a controlled path between the clamps, effectively managing cable shape and reducing unwanted bent portions
3Reliability
If axis shift state is applied to cable holding portions, then deflection width is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The asymmetric axial positioning structure serves multiple functions simultaneously: it prevents cable interference, absorbs cable length variations, and provides stable positioning. By integrating these functions into a single structural arrangement rather than requiring separate components, the patent reduces the impact on manufacturing precision requirements
Data Source
AI summary
A cable extra length absorbing structure includes a pair of cable clamps. The pair of cable clamps are disposed at a predetermined interval on one side portion of one structural member or one side portions arranged on the same side in two structural members. The pair of cable clamps respectively include cable holding portions arranged on a path in which a cable is configured to be wired. Tach of the cable holding portions includes a holding space. The cable holding portions are disposed in an axis shift state in which a center axis of one holding portion is shifted with respect to a center axis of the other holding portion.