Divided Bus Bar Holder Press-Fit for Battery Stack Assembly
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Solution Overview
Problem
The existing power supply device assembly process for vehicles is inefficient due to the need for strong pressing of battery stacked members, which leads to decreased productivity and potential misalignment of bus bars during the assembly of battery cells connected in series.
Innovation Solution
A power supply device design featuring a divided bus bar holder with a press-fitting structure, including an intermediate holder and side surface holders, allows for early release of pressure during assembly, improving efficiency and preventing misalignment by using a hook portion and engaging portion for secure fixation, along with insulating spacers and a circuit board positioning system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If strong pressing is applied to bind the battery stacked member by binding bars, then the binding strength is improved, but the assembly time is increased and productivity is decreased
Solution Approach 1:
The binding structure is segmented into multiple binding bars (first binding bar and second binding bar) that can be installed independently at different stages. This allows the binding process to be divided into manageable steps, reducing the time required for each pressing operation while achieving the required binding strength through cumulative effect.
Solution Approach 2:
The bus bar holder is preliminarily fixed to the battery stacked member before the binding bars are fully installed. This preliminary action allows the battery stacked member to be bound in advance, enabling earlier release of pressing force and improving assembly efficiency without compromising final binding strength.
2Stability of the object's composition
If strong pressing is maintained during bus bar holder fixation, then the fixation stability is improved, but the assembly efficiency is decreased due to prolonged pressing time
Solution Approach 1:
The bus bar holder is fixed preliminarily during the assembly process before the binding bars are completely installed. This preliminary fixation maintains stability during the critical phases while allowing the pressing force to be released earlier than in conventional methods, thereby improving assembly efficiency without sacrificing fixation stability.
Solution Approach 2:
The fixation process is segmented into multiple stages: preliminary fixation of the bus bar holder, followed by progressive installation of binding bars. This segmentation allows stability to be maintained at each stage while reducing the total duration of strong pressing required, thus improving overall assembly efficiency.
3Strength
If the bus bar holder is fixed after binding bars are installed, then the structural integrity is improved, but the assembly complexity is increased and productivity is decreased
Solution Approach 1:
The bus bar holder is installed and preliminarily fixed before the binding bars are completely secured. This preliminary action simplifies the assembly sequence by allowing the bus bar holder to be positioned and secured during the binding process itself, rather than requiring a separate fixation step after all binding bars are installed, thereby reducing assembly complexity while maintaining structural integrity.
Data Source
AI summary
A power supply device comprises plural battery cells having a rectangular box shape and electrode terminals, a binding member binding a battery stacked member stacking the battery cells, bus bars connecting electrode terminals of the battery cells, and an insulating bus bar holder covering the upper surface of the battery stacked member. The binding member binds the battery stacked member at the side surface and upper surface thereof. The binding member comprises a side covering portion covering the side surface of the battery stacked member, and an upper covering portion covering the upper surface of the battery stacked member. The bus bar holder is divided into an intermediate holder located at the intermediate portion, and side surface holders located at the side surfaces of both sides of the intermediate holder. The side surface holder and the intermediate holder are press-fitted by a press-fitting structure.