Finger-Proof Bolted Bus Bar Assembly for Live Terminal Access
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Solution Overview
Problem
Existing battery module connections pose a shock hazard and require safe electrical connection and disconnection methods to prevent accidental contact with live terminals during assembly and servicing.
Innovation Solution
A bus bar assembly with a nonconductive terminal cap and shroud that secures to an electrically conductive terminal, featuring a finger-proof design meeting IP2XB standard, ensuring safe assembly and handling by enclosing the terminal and allowing secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is exposed to allow electrical connection, then electrical connectivity is achieved, but shock hazard increases due to accidental contact with live terminals
Solution Approach 1:
The terminal cap is segmented with a slot that exposes only the terminal portion necessary for electrical connection while enclosing the rest of the terminal. This segmentation allows the terminal to be divided into exposed (conductive) and enclosed (protected) sections, resolving the contradiction by providing electrical connectivity where needed while preventing shock hazard in other areas.
Solution Approach 2:
The terminal cap acts as an intermediary protective element between the live terminal and the user's hand. It mediates the interaction by allowing tool-based electrical connection while blocking direct finger contact, thus enabling electrical connectivity function while eliminating the shock hazard.
2Object-affected harmful factors
If the terminal is enclosed to prevent accidental contact, then safety is improved, but access for electrical connection becomes difficult
Solution Approach 1:
The terminal cap applies local quality by providing different properties in different areas: the slot area is open to allow tool access for electrical connection, while the rest of the cap is enclosed to prevent finger contact. This localized differentiation resolves the contradiction by optimizing both safety and operability in their respective zones.
Solution Approach 2:
The terminal cap design dynamically balances protection and access: it remains enclosed for safety during normal handling, but allows dynamic tool access through the slot when connection is needed. The design adapts to different operational states (handling vs. connecting) without compromising either safety or ease of operation.
3Object-affected harmful factors
If a protective cover is added to enclose the terminal, then safety is improved, but device complexity increases
Solution Approach 1:
The terminal cap merges multiple functions into a single component: it provides shock hazard protection, enables tool-based electrical connection through the slot, and secures to the bus bar assembly. By combining these functions in one integrated part, the design improves safety without proportionally increasing device complexity.
Solution Approach 2:
The terminal cap serves multiple universal functions: protective enclosure, connection access facilitation, and structural attachment. This multi-functionality resolves the contradiction by achieving safety improvement while minimizing complexity increase, as one component performs several critical roles.
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
A bus bar assembly (16) includes a nonconductive terminal cap (22) that is configured to secure to an electrically conductive terminal via an attachment feature (24). The terminal cap (22) has a slot (54) that is configured to expose a terminal portion (19) of the terminal (14) in an assembled condition. A bus bar (40) has an end (52) that is configured to be received in the slot (54) in the assembled condition in which the end (52) is in electrical contact with the terminal portion (19) of the terminal (14). A nonconductive shroud (26) encloses the bus bar (40). The end (52) extends through shroud (26).