Battery Module Cell Connector Centering for Precise Assembly
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Solution Overview
Problem
Existing battery module connections, particularly those using cables and stamped bent parts, face challenges in repeatable orientation, precise positioning, and high risk of loose connections, leading to safety issues and manufacturing inefficiencies.
Innovation Solution
A battery module housing with a centering unit for cell connectors that ensures accurate positioning and automated assembly, using stamped bent parts for connections, and allows for flexible centering elements to compensate for manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cables are used for connections, then flexibility is achieved, but repeatable orientation and precise positioning become impossible
Solution Approach 1:
The connection system is segmented into rigid stamped bent parts for structural connection and flexible cables for electrical connection. The stamped bent parts provide precise positioning and repeatable orientation, while the cables maintain flexibility for electrical connectivity without compromising positioning precision.
Solution Approach 2:
The invention combines stamped bent parts and cables into a hybrid connection system. The stamped bent parts are integrated with cable assemblies to achieve both precise mechanical positioning and flexible electrical connection, resolving the contradiction between rigidity and flexibility.
2Manufacturing precision
If manual connection is used, then positioning can be adjusted, but manufacturing efficiency and automation become compromised
Solution Approach 1:
The connection components (stamped bent parts and cable assemblies) are pre-assembled and pre-positioned with precise orientation before installation into the battery module. This preliminary action enables automated installation while maintaining high connection accuracy, eliminating the need for manual adjustment during assembly.
Solution Approach 2:
The stamped bent parts are designed with self-aligning features that automatically position the cable assemblies correctly during automated assembly. The components guide themselves into the proper position, enabling high-speed automated manufacturing while maintaining precise connection accuracy without manual intervention.
3Reliability
If stamped bent parts are used, then connection stability is improved, but adaptability and tolerance compensation become limited
Solution Approach 1:
The invention uses flexible cables with adjustable parameters (length, routing, tension) to compensate for manufacturing tolerances in the rigid stamped bent parts. By varying these parameters, the system adapts to tolerance variations while maintaining stable electrical connections, reconciling rigidity with adaptability.
4Ease of manufacture
If loose connections occur, then ease of assembly is improved, but safety and reliability deteriorate
Solution Approach 1:
The connection system incorporates pre-assembled units with built-in cushioning elements and securement features that prevent loose connections before they can cause safety issues. The stamped bent parts and cable assemblies are pre-configured with tolerance compensation capabilities that maintain secure connections during assembly variations, ensuring safety without compromising assembly ease.
Data Source
AI summary
A battery module housing for receiving multiple battery cells having: multiple receiving regions for the battery cells, battery cell receiving regions, a receiving region for a circuit board, circuit board receiving region that lies adjacent to the battery cells receiving regions; and multiple receiving regions for cell connectors, cell connector receiving regions that are provided adjacent to some of the battery cell receiving regions. At least one centering unit is provided for a cell connector within at least one of the cell connector receiving regions.