Direct-Mounted Contactor Assembly for Simpler Battery Bussing
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Solution Overview
Problem
Existing bussed electrical centers for traction batteries are costly and complex due to the use of injection-molded housings and stamped busbars, requiring complex assembly and tooling.
Innovation Solution
Directly mounting components such as pre-charge circuits, fuses, and capacitors to contactors, which are then secured to a support structure, eliminating the need for large injection-molded housings and reducing the use of busbars, allowing for simpler and more cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection-molded housings and stamped busbars are used, then structural integrity and electrical connectivity are ensured, but manufacturing cost and device complexity increase
Solution Approach 1:
The contactor housing serves dual purposes: it provides structural support and acts as the mounting surface for the pre-charge module. This integration eliminates the need for separate mounting structures and reduces the number of components, thereby lowering manufacturing cost and assembly complexity while maintaining structural integrity
Solution Approach 2:
The contactor housing is designed to perform multiple functions: it houses the contactor switching mechanism, provides structural support for the battery assembly, and serves as the mounting base for the pre-charge module. This multi-functionality reduces the overall component count and simplifies the device structure
2Reliability
If injection-molded housings and stamped busbars are used, then electrical connectivity is ensured, but manufacturing cost increases
Solution Approach 1:
The pre-charge module is directly integrated with the contactor housing, eliminating the need for separate mounting structures and reducing the number of manufacturing steps. This integration lowers tooling costs and simplifies production while ensuring reliable electrical connectivity through direct mechanical and electrical coupling
Solution Approach 2:
The electrical system is segmented into modular components (contactor, pre-charge module) that can be manufactured and assembled independently. This modularity allows for simpler manufacturing processes for each component while ensuring reliable electrical connections through standardized interfaces
3Ease of operation
If large injection-molded housings are used, then component mounting is facilitated, but device complexity and cost increase
Solution Approach 1:
The pre-charge module is directly mounted on the contactor housing, which serves as both the structural support and the mounting surface. This eliminates the need for large separate housings and complex mounting structures, simplifying the overall device while facilitating component assembly
Solution Approach 2:
Instead of mounting the contactor to a large housing structure, the pre-charge module is mounted directly to the contactor housing. This inversion of the traditional mounting approach eliminates the need for large injection-molded housings while still providing adequate mounting surfaces
Data Source
AI summary
A traction battery assembly includes a traction battery having a plurality of cells secured in one or more arrays by support structure. A contactor is electrically connected to the traction battery and has a housing mounted to the support structure, a pair of terminals extending from the housing, and a switching arrangement configured to electrically connect the terminals when closed. A pre-charge module is connected to the traction battery solely through direct attachment to the contactor. The module has a pre-charge circuit electrically connected to the terminals and a case that is directly attached to the housing of the contactor.