EV Battery Cover Rigidity via Lock Position Adjustment
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Solution Overview
Problem
The existing power supply devices for hybrid and electric vehicles have covers that are low in rigidity due to numerous hinge portions, making them easily deformable and prone to tolerance issues during assembly.
Innovation Solution
A power supply device design featuring a cover with fewer or no flexural deformation portions, utilizing lock portions with changeable or fixed relative positions and clamping ribs to absorb tolerance variations, increasing rigidity and reducing deformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If numerous hinge portions are used to connect terminal fixing portions and wire housing portions, then the cover can absorb tolerance variations during assembly, but the cover becomes low in rigidity and easily deformable
Solution Approach 1:
The cover is divided into multiple terminal fixing portions and wire housing portions that are connected via hinge portions. This segmentation allows each portion to move independently to absorb assembly tolerances while maintaining overall cover functionality.
Solution Approach 2:
The hinge portions are strategically placed only at specific locations where tolerance absorption is needed, rather than making the entire cover flexible. This localized flexibility maintains rigidity in areas where structural stability is critical.
2Strength
If the cover is made with fewer or no hinge portions to increase rigidity, then the cover becomes less deformable and more rigid, but the ability to absorb tolerance variations during assembly is reduced
Solution Approach 1:
The hinge portions provide controlled dynamic movement between cover components, allowing the cover to adapt to tolerance variations during assembly while maintaining overall structural integrity and rigidity.
Solution Approach 2:
The hinge portions act as flexible connection elements that allow limited movement between rigid cover components, enabling tolerance absorption without compromising the overall rigidity of the cover structure.
3Ease of manufacture
If multiple split cover portions are used to cover terminal fixing portions, then the cover can be easily assembled and disassembled, but the cover becomes low in rigidity due to numerous hinge portions
Solution Approach 1:
The cover is segmented into multiple split cover portions that can be independently assembled and disassembled, facilitating easy manufacturing and maintenance while maintaining structural integrity through strategic hinge placement.
Solution Approach 2:
Multiple split cover portions are merged into a unified cover structure that provides both ease of assembly/disassembly and sufficient rigidity, by combining flexible hinge connections with rigid terminal fixing portions.
Data Source
AI summary
A power supply device includes a battery cell assembly being an assembly of battery cells each having electrodes, a battery connecting block including a case body including terminal fixing portions connected to each other via flexural deformation portions and a cover fixed to the case body and configured to cover the terminal fixing portions, and lock portions provided to the cover and the case body with intervals in a longitudinal direction. A lock portion other than lock portions located at two end positions in the longitudinal direction is configured to be capable of locking the cover with the case body with a changeable relative lock position of the cover and the case body in the longitudinal direction.