Battery Cell Connector Assembly for Error-Proof Voltage Taps
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Solution Overview
Problem
Existing rechargeable battery packs for gardening and forestry work appliances face challenges in simple and efficient assembly, leading to complex and error-prone connections.
Innovation Solution
A cell connector structure comprising a plurality of cell connectors, cell connector elements, voltage tap elements, and tap element bodies, designed for easy assembly and secure connection, allowing for direct arrangement and securing of components without complex steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional assembly methods are used for cell connector structures, then connection reliability is maintained, but assembly complexity increases and assembly time is extended
Solution Approach 1:
The cell connector structure is divided into separate components: cell connectors, cell connector elements, voltage tap elements, and tap element bodies. These components can be assembled independently and then connected together, allowing parallel assembly processes and reducing overall assembly complexity while maintaining connection reliability.
Solution Approach 2:
Cell connectors are pre-assembled onto cell connector elements, and voltage tap elements are pre-assembled onto tap element bodies before the final connection. This preliminary assembly allows for quality control and preparation to occur separately, reducing the complexity of the final assembly step while ensuring reliable connections.
2Device complexity
If direct connection methods are used for cell connectors and voltage tap elements, then assembly steps are reduced, but the risk of incorrect assembly increases
Solution Approach 1:
The cell connector elements and tap element bodies are designed with asymmetric features including protrusions and recessions that only fit together in the correct orientation. This asymmetric design ensures that components can only be assembled in the proper configuration, eliminating incorrect assembly while maintaining a simple direct connection process.
Solution Approach 2:
The cell connector elements and tap element bodies act as intermediary components between the cell connectors and voltage tap elements. These intermediaries provide built-in alignment and positioning features that guide the assembly process, ensuring correct positioning without requiring complex assembly procedures.
3Reliability
If components are secured against becoming detached, then connection reliability is improved, but assembly complexity increases
Solution Approach 1:
The securing features are integrated directly into the cell connector elements and tap element bodies rather than being separate components. The protrusions and recessions that provide mechanical connection also serve as the securing mechanism, combining the connection and securing functions into a single integrated feature that improves reliability without adding assembly complexity.
Solution Approach 2:
The asymmetric protrusion and recession design enables self-aligning and self-securing during assembly. When the components are brought together, the geometric features automatically guide them into the correct position and lock them in place without requiring additional securing steps or complex mechanisms, achieving reliable connection through the basic connection geometry itself.
Data Source
AI summary
A cell connector structure is provided for a rechargeable battery pack that supplies electrical drive power to an electrically driven gardening and/or forestry work appliance. The cell connector structure has: a plurality of cell connectors, wherein the cell connectors are designed for electrically connecting rechargeable battery cells, at least one cell connector element, wherein the cell connectors and the at least one cell connector element are designed for being arranged on one another and for being secured against becoming detached from one another, a plurality of voltage tap elements, wherein the voltage tap elements have voltage tap cables, wherein the voltage tap cables are designed for being electrically connected to the cell connectors, and at least one tap element body, wherein the voltage tap elements and the at least one tap element body are designed for being arranged on another and for being secured against becoming detached from one another. The at least one cell connector element with the cell connectors and the at least one tap element body with the voltage tap elements are designed for being mechanically connected to one another.