Elastic Bus Bar Structure for Gap-Free Battery Terminal Welding
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Solution Overview
Problem
The challenge in connecting battery cells via bus bars is the difficulty in ensuring precise alignment and welding due to dimensional errors, leading to gaps and unreliable connections, especially when thick bus bars are required for high current applications.
Innovation Solution
A bus bar design with elastically deformable arm portions connected to a rod portion, allowing the distal end to adjust and weld securely to the electrode terminal, eliminating gaps and ensuring reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a power supply device is disposed in each vehicle body to supply power to auxiliary devices, then each auxiliary device can be supplied with power independently, but the device complexity and cost increase due to requiring multiple power storage devices
Solution Approach 1:
The power supply system is segmented into a main power storage device in the power supply vehicle and auxiliary power storage devices in each vehicle body. The main power storage device is divided into multiple battery modules that can independently supply power to different vehicle bodies, enabling independent power supply while maintaining system manageability.
Solution Approach 2:
A power supply device acts as an intermediary between the main power storage device and the auxiliary devices in vehicle bodies. This intermediary device receives power from the main storage device and distributes it to auxiliary devices, eliminating the need for each vehicle body to have its own large power storage device while ensuring reliable power supply.
2Ease of operation
If power storage devices are disposed in both the power supply vehicle and each vehicle body, then power can be supplied to each vehicle body independently, but the cost and device quantity increase
Solution Approach 1:
Multiple power storage functions are merged into a single main power storage device in the power supply vehicle. This main device contains multiple battery modules that collectively provide power to multiple vehicle bodies, reducing the total number of power storage devices while maintaining independent power supply capability through the power supply device intermediaries.
3Quantity of substance
If a large-capacity power storage device is disposed in the power supply vehicle to supply power to multiple vehicle bodies, then the number of power storage devices is reduced, but the weight and volume of the power supply vehicle increase
Solution Approach 1:
The large power storage device is segmented into multiple battery modules of appropriate capacity. Each module can supply power to one or more vehicle bodies, reducing the weight and volume requirements for the main power storage device while maintaining the capability to supply multiple vehicle bodies.
4Adaptability or versatility
If power storage devices with appropriate capacity are disposed in each vehicle body, then each vehicle body can be supplied with appropriate power, but the total weight and volume of power storage devices increase
Solution Approach 1:
The power supply device is designed with universal functionality to work with different vehicle bodies and auxiliary devices. It can receive power from the main power storage device and distribute it to various auxiliary devices in different vehicle bodies, providing adaptability without requiring each vehicle body to have its own dedicated power storage device.
Data Source
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AI summary
To weld a bus bar and an electrode terminal with certainty by bringing the bus bar and the electrode terminal into close contact with each other without forming a gap between the bus bar and the electrode terminal, provided is a power supply device that is a power supply device including a plurality of battery cells electrically connected with each other by bus bar (3). The power supply device has a structure where bus bar (3) includes: rod (4) having conductivity and extending in an arrangement direction of the battery cells; and arm (5) being elastically deformable and being connected to rod (4), arm (5) is configured such that distal end (5x) of arm (5) is welded to an electrode terminal of the battery cell, and rear end (5y) of arm (5) is connected to rod (4) so as to electrically connect the plurality of battery cells to each other via the rod, arm (5) is formed of a conductive plate that is elastically deformable, deformation gap (6) extending from rear end (5y) toward a distal end is formed between arm (5) and rod (4), and arm (5) is elastically deformable so as to displace distal end (5x) to be welded to the electrode terminal.