Flexible Busbar Cover with Rotating Protrusions for Quick Access
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Solution Overview
Problem
The existing busbar modules in electric storage systems of vehicles face inefficiencies in connecting external devices due to the need to open and close covers, exposing busbars to dust and moisture, which reduces work efficiency and increases the risk of damage.
Innovation Solution
A busbar module design featuring a flexible busbar cover with protrusions that deform to allow easy attachment and rotation, enabling quick exposure of the busbar for device connection while maintaining protection from foreign substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cover is opened to connect external devices to the busbar, then the connection operation can be performed, but the busbar is exposed to foreign substances such as dust and moisture
Solution Approach 1:
The busbar is nested within the cover structure, with the cover forming a protective enclosure that can be opened only at designated access portions. This allows the busbar to remain protected while enabling connection operations through the openings in the cover.
Solution Approach 2:
The cover is segmented with multiple opening portions at different locations, allowing selective access to different busbar connection points. This enables connection operations to be performed at specific locations without exposing the entire busbar structure to foreign substances.
2Ease of operation
If the cover is repeatedly opened and closed for connection operations, then external devices can be connected, but the work efficiency is reduced
Solution Approach 1:
The cover is pre-configured with opening portions at strategic locations that provide direct access to busbar connection points. This preliminary design eliminates the need for complete cover removal or complex opening sequences, allowing connection operations to be performed quickly and efficiently.
3Ease of operation
If the busbar is exposed for connection operations, then external devices can be connected, but the reliability is reduced due to risk of damage from foreign substances
Solution Approach 1:
The busbar is nested within the cover structure, with the cover forming a protective enclosure that can be opened only at designated access portions. This allows the busbar to remain protected while enabling connection operations through the openings in the cover.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves work efficiency by simplifying the connection process of external devices to busbars and ensures the busbars remain protected from dust and moisture, enhancing reliability and durability.
Implementation Method 1
The busbar cover is flexible to deform such that the gap between the protrusions expands in the axial direction to allow the wall of the bearing to pass through the gap during attachment of the busbar cover to the busbar holding plate
Data Source
AI summary
A busbar module includes a busbar holding plate and a busbar cover attached to the busbar holding plate. The busbar holding plate includes a busbar holding face and a bearing including a hole and a wall to define the hole. The busbar cover includes protrusions protruding toward each other in the axial direction at positions corresponding to the hole. The protrusions are opposed to each other with a gap less than a dimension of the hole in the axial direction. The protrusions are disposed in the hole to rotate the busbar cover about the protrusions between a covering position and an uncovering position. The busbar cover is flexible to deform such that the gap expands to allow the wall to pass through the gap during attachment of the bulbar cover to the busbar holding plate and restores its original shape when passing of the wall through the gap is complete.