Connection Module Busbar Torque Load Mitigation
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Solution Overview
Problem
The existing connection modules for electricity storage element groups with elongated external connection busbars face reliability issues due to torque loads applied during bolt connection, which can affect the connection between the busbars and the output electrode terminals.
Innovation Solution
A connection module with a busbar holding module and an external connection busbar holding portion, featuring a first and second external connection busbar, an insulating protector, and a protector portion that engages with the busbar holding module to mitigate torque loads, ensuring stable connection between the elongated external connection busbar and the output electrode terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If an elongated external connection busbar is used to connect output electrode terminals at opposite ends of the electricity storage element group, then the power supply distance is extended, but the connection reliability deteriorates due to torque load from bolting external connection components
Solution Approach 1:
The holding member is divided into a first holding portion and a second holding portion that are separated from each other. The first holding portion holds the first external connection busbar, while the second holding portion holds the second external connection busbar. This segmentation allows each holding portion to independently support its respective busbar, preventing torque load from being transmitted to the other busbar and maintaining connection reliability.
2Ease of operation
If external connection components are bolted to the external connection busbar, then the connection to external devices is established, but torque load is applied to the connection portion between the busbar and output electrode terminal, affecting connection reliability
Solution Approach 1:
The harmful torque load generated during bolting is extracted and isolated from the busbar connection to the output electrode terminal. The holding member provides a separate mounting structure for external connection components, allowing bolts to be secured to the holding member rather than directly to the busbar connection point, thereby removing the adverse torque effect from the critical connection.
Solution Approach 2:
The holding member acts as an intermediary between the external connection components and the busbar system. Instead of directly bolting external components to the busbar (which creates torque load), the holding member serves as a mediator that absorbs and isolates the torque, allowing secure external connections without compromising the busbar-to-terminal connection reliability.
3Device complexity
If a single holding member is used to hold both external connection busbars, then the structure is simplified, but torque load from one busbar can affect the other busbar connection
Solution Approach 1:
The holding member is segmented into distinct first and second holding portions with different orientations. The first holding portion extends in a first direction to hold the first external connection busbar, while the second holding portion extends in a second direction (perpendicular to the first direction) to hold the second external connection busbar. This segmented structure prevents torque load from being transmitted between busbars while maintaining overall structural integration.
Solution Approach 2:
Different portions of the holding member are designed with different local qualities and orientations. The first holding portion is configured to optimally support the first busbar in one direction, while the second holding portion is configured to optimally support the second busbar in a perpendicular direction. This local differentiation allows each portion to independently manage its respective busbar's mechanical loads without interfering with the other.
Data Source
AI summary
A connection module includes a busbar holding module, and an external connection busbar holding portion that is disposed on the busbar holding module. The busbar holding module includes an insulating protector configured to hold a plurality of busbars. The external connection busbar holding portion includes a first external connection busbar having an elongated shape, a second external connection busbar to which an external connection component is to be bolted, and an external connection busbar protector. The insulating protector includes a first engaging portion configured to be engaged with the external connection busbar protector, and the external connection busbar protector includes a first engaged portion configured to be engaged with the first engaging portion.