Detection Terminal Reinforcing Portion for Bus Bar Welding
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Solution Overview
Problem
The existing methods for connecting detection terminals to bus bars using laser welding face challenges, such as the risk of terminal bending and potential welding failures due to gaps between the terminal and the bus bar, which can lead to unreliable connections.
Innovation Solution
A detection terminal design that includes a welded portion, a locked portion to secure the terminal on the bus bar, and a reinforcing portion to prevent bending deformation, ensuring the terminal remains in close contact and flat, allowing for reliable laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the detection terminal is rotated and overlaid on the bus bar after the locking piece is passed through the locking hole, then the detection terminal can be connected to the bus bar, but there is a risk that the detection terminal will be bent and a gap will be formed between the detection terminal and the bus bar
Solution Approach 1:
The reinforcing portion is formed in advance on the detection terminal before the connection process. This preliminary structural preparation prevents bending deformation during the rotation and overlay operation, ensuring the detection terminal maintains its flat shape throughout the connection process without requiring additional real-time corrections.
Solution Approach 2:
The reinforcing portion acts as a preventive measure against bending deformation before it can occur. By providing additional structural support in advance, the design counteracts the bending forces that would naturally occur during rotation and overlay, preventing the formation of gaps between the detection terminal and bus bar.
2Productivity
If laser welding is used to connect the detection terminal to the bus bar, then connection speed and strength are improved, but the detection terminal must be precisely positioned and maintained flat to avoid welding failure
Solution Approach 1:
The reinforcing portion is prepared in advance to maintain the flat shape of the detection terminal during positioning and welding operations. This preliminary structural reinforcement ensures that the terminal remains stable and gap-free throughout the laser welding process, enabling reliable welding without requiring complex positioning adjustments during operation.
3Ease of operation
If the detection terminal is made thin and flexible for easy installation, then ease of operation is improved, but the terminal becomes prone to bending deformation under load
Solution Approach 1:
The detection terminal is divided into functionally distinct portions: a thin, flexible main body for ease of installation and a localized reinforcing portion for structural support. This segmentation allows the terminal to maintain flexibility where needed while providing targeted reinforcement to prevent bending deformation under load, resolving the contradiction between thinness and strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures strong and reliable welding of the detection terminal onto the bus bar, even under excessive loads, by maintaining the welded portion in a flat shape, thus preventing deformation and ensuring a consistent, gap-free connection.
Implementation Method 1
a method of performing connection using laser welding instead of fastening with bolts and nuts
Data Source
AI summary
A wiring module comprising: a bus bar that connects adjacent electrode terminals of a plurality of single batteries each having positive and negative electrode terminals; and a detection terminal that is overlaid on the bus bar and is for detecting a state of a single battery among the plurality of single batteries. The detection terminal is provided with a welded portion welded onto the bus bar, a locked portion that locks to a locking portion provided on the bus bar and holds the detection terminal in a state in which the welded portion is overlaid on the bus bar, and a reinforcing portion that prevents the welded portion from performing a bending deformation so as to keep the welded portion in a flat plate shape overlaid on the bus bar.