Battery Cell Contacting Assembly for Automated Signal Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing cell contacting arrangements for energy storage modules, particularly in electric and hybrid vehicles, are expensive and prone to faults due to the manual connection of signal lines to cell connectors, which requires corrosion protection and involves costly and error-prone processes.
Innovation Solution
A cell contacting arrangement that includes a connecting element with spatial orientation elements to facilitate automated and precise connection between signal lines and cell connectors, eliminating the need for additional corrosion protection and reducing manual intervention, using materials like copper and aluminum with a seamless transition to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual connection of signal line to cell connector is used, then connection can be established, but production cost increases and fault susceptibility increases
Solution Approach 1:
The connecting element is designed with self-aligning features including a guide section that automatically guides the signal line onto the connecting element during automated assembly, eliminating the need for manual positioning and reducing production costs while maintaining connection reliability
Solution Approach 2:
The connecting element acts as an intermediary component between the signal line and cell connector, providing a standardized interface that enables automated connection processes and reduces both cost and fault susceptibility
2Object-affected harmful factors
If corrosion protection coating is applied manually, then corrosion protection is achieved, but production process becomes expensive and fault-prone
Solution Approach 1:
The connecting element uses composite material construction with a copper section for electrical conductivity and an aluminum section for lightweight properties, with a seamless transition zone that provides inherent corrosion protection without requiring additional coating processes
Solution Approach 2:
The corrosion protection function is merged into the material composition and structural design of the connecting element itself, eliminating the need for separate corrosion protection coating steps and reducing production complexity
3Extent of automation
If automated corrosion protection coating is applied, then some automation is achieved, but large amounts of coating material are wasted due to poor positioning tolerance
Solution Approach 1:
The corrosion protection function is extracted from the coating process and integrated into the connecting element's material composition and structure, eliminating the need for coating material entirely and preventing waste
4Manufacturing precision
If spatial orientation element is added to connecting element, then automated assembly precision improves, but device complexity increases
Solution Approach 1:
The connecting element is segmented into functional sections including a guide section for positioning, a transition zone for material integration, and connection terminals, with each segment serving a specific purpose that collectively enables automated assembly without excessive complexity
Data Source
AI summary
A cell contacting arrangement is provided for an energy storage module having at least one energy storage cell, each storage cell having at least two connection terminals. The cell contacting arrangement has a carrier plate which can be arranged on the energy storage module, a cable harness which is carried by the carrier plate and has a plurality of signal lines, and a plurality of cell connectors which are inserted into the carrier plate or integrated into the carrier plate and are designed to connect a connection terminal of the storage cell and a signal line of the cable harness. There is also a connection element which has a first end which can be connected to the signal line and a second end which can be connected to the cell connector. The carrier plate and/or the cell connector has at least one spatial orientation element which defines the spatial orientation between the connection element and the cell connector and/or the carrier plate.