Detachable Voltage Sensing Module With Locking Mechanism
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Solution Overview
Problem
Conventional voltage sensing modules in battery packs are inconvenient to assemble and maintain due to soldered bus bars, which can lead to damage and short-circuits during the soldering process, and require replacement of the entire module when the substrate is faulty, especially in vehicles prone to shaking and shocks.
Innovation Solution
A detachable voltage sensing module with bus bars that are detachably mounted to a substrate using jack terminals and elastic holders, allowing for easy assembly and replacement of the substrate without soldering, featuring a locking mechanism to secure the substrate to the body and prevent bus bar separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are soldered to the substrate, then electrical connection is achieved, but assembly convenience deteriorates and repairability worsens
Solution Approach 1:
The voltage sensing module is divided into separable components: the substrate with control circuit, the bus bars for electrical connection, and the locking means for mechanical attachment. This segmentation allows the substrate to be replaced independently without affecting the bus bars or requiring soldering, thus improving assembly convenience while maintaining reliable electrical connections through the locking mechanism and jack terminals.
2Reliability
If bus bars are soldered to the substrate, then electrical connection is achieved, but manufacturing complexity increases due to soldering process
Solution Approach 1:
The soldering process (thermal/chemical joining method) is replaced with a mechanical locking system consisting of locking means and jack terminals. This substitution eliminates the need for soldering equipment, heating processes, and complex manufacturing steps, thereby simplifying the manufacturing process while ensuring reliable electrical connection through the mechanical-electrical integrated locking structure.
3Reliability
If substrate is fixed with soldered bus bars, then electrical connection is stable, but replaceability of substrate deteriorates
Solution Approach 1:
The connection between substrate and bus bars is made dynamic and reversible through the locking means and jack terminals. The locking mechanism allows for easy engagement and disengagement, enabling the substrate to be replaced when damaged or faulty without permanently fixing it to the bus bars. This dynamic connection maintains stable electrical contact during operation while facilitating quick replacement during maintenance.
4Strength
If bus bars are fixedly mounted to substrate, then structural integrity is improved, but maintenance complexity increases
Solution Approach 1:
The voltage sensing module is segmented into maintainable components where the substrate can be independently accessed and replaced. The locking means provide sufficient structural integrity to keep the bus bars securely mounted during normal operation, while allowing the substrate to be quickly removed and replaced during maintenance without compromising the overall structural strength of the assembly.
Data Source
AI summary
The present invention relates to a detachable voltage sensing module and a battery device having same. The voltage sensing module comprises: a body on which are fixed a plurality of bus bars, which are connected to the cell tabs of battery cells; a substrate on which a control circuit is formed and which is detachably attached to the body; a jack terminal, disposed on the substrate, for connecting the battery cells to the substrate, when the substrate is being attached to the body, by connecting to one end of each of the bus bars; and a fixing means for fixing the substrate to the body. A detachable voltage sensing module formed as described above and a battery device having same, according to the present invention, are formed such that bus bars can be assembled on or disassembled from a substrate, and thus the substrate can be replaced at any time, thereby enabling easy assembly, maintenance and repair.