Flexible Connector System for Battery Module Wiring Simplification

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Solution Overview

Problem

Battery systems in heavy-duty electric vehicles, such as those used in underground mining, face challenges with complex and entangled wiring that increases repair costs and downtime due to the need for sophisticated equipment and increased offline time for maintenance.

Innovation Solution

A flexible connector system with a central spine and multiple arms that organize electrical connections, allowing for easier servicing and replacement, featuring a unified array of electrical connections that reduces the complexity of wiring and minimizes the risk of incorrect connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If multiple separate wires are used to connect battery components, then electrical connections can be established, but the wiring becomes entangled and complex making repair difficult

Engineering Contradiction:

Improveease of repairVSAvoidwiring complexity

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

Multiple separate wires are merged into a single flat flexible connector that contains all necessary electrical connections in one organized structure. This unified connector eliminates entanglement and complexity while maintaining all required electrical connections between battery components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flat flexible connector is divided into multiple arms or sections, each containing specific wires for different electrical connections. This segmentation allows service persons to access and repair specific connections independently without dealing with a tangled mass of wires.

Inventive Principle:

Principle #1Segmentation

2Reliability

If complex wiring systems are used in battery modules, then complete electrical connections are achieved, but repair requires sophisticated equipment and increased offline time

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidrepair downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

All electrical connections are pre-organized and pre-assembled within the flat flexible connector during manufacturing. This preliminary organization ensures reliable electrical connections while enabling rapid repair, as the pre-structured connector can be quickly replaced or serviced without complex field assembly procedures.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If multiple separate connectors are used for battery cells, then individual connections can be made, but the overall system becomes harder to service

Engineering Contradiction:

Improvemanufacturing easeVSAvoidservicing ease

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

Multiple individual connectors are merged into a single flat flexible connector assembly that maintains all necessary connection points. This unified structure is easier to manufacture as a single component while dramatically improving servicing ease, as technicians can access and service all connections through one organized interface rather than navigating multiple separate connectors.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11101527B2Method of assembly of a battery module with unified connection array

Publication Date: 2021.08.24 SANDVIK MINING & CONSTR OY

AI summary

A method for assembling a battery module including a unified connection array with a flexible connector is described. The flexible connector can include a plurality of pads that are secured to a central spine. The flexible connector may be a single piece connector. The flexible connector can include monitors that are mounted to the flexible connector to gather data regarding battery cells of the battery module.