Folded Wiring Module for Battery Gap Tolerance
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Solution Overview
Problem
Conventional high-voltage electric cable connections for power storage element groups in vehicles have low flexibility, leading to cable misalignment and interference with work processes due to tolerance issues between battery groups, necessitating short cable lengths that still result in undesired projections.
Innovation Solution
A wiring module with a folded-back electric cable configuration, utilizing a connection member, insulating protector, and holding part with a hook shape to absorb gap tolerance and maintain cable position, ensuring non-interfering workability before connection to an external member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the high-voltage electric cable is made long to absorb gap tolerance, then the tolerance of the gap between battery groups can be absorbed, but the cable projects to undesired positions and interrupts work
Solution Approach 1:
The cable path is segmented into multiple sections: a first section from the first battery group to the holding part, and a second section from the holding part to the second battery group. The holding part acts as an intermediate segmentation point that allows the cable to change direction and be held at a position that absorbs gap tolerance without projecting to undesired positions.
Solution Approach 2:
The holding part serves as an intermediary component between the two battery groups. It holds the cable at a specific position, allowing the cable to absorb gap tolerance while preventing the cable from projecting to undesired positions that would interrupt work. The holding part mediates between the need for long cable and workability requirements.
2Ease of operation
If the high-voltage electric cable is made short to improve workability, then the cable does not project to undesired positions, but it is difficult to absorb the tolerance of the gap between battery groups
Solution Approach 1:
By segmenting the cable path through the holding part, the system achieves both short effective cable lengths for good workability and sufficient total length for gap tolerance absorption. The first and second sections together provide the necessary length while the holding part ensures proper positioning.
Solution Approach 2:
The holding part introduces a spatial dimension change by holding the cable at a specific position that is offset from the direct line between battery groups. This allows the cable to absorb gap tolerance in one dimension while maintaining good workability in other dimensions by not projecting to undesired positions.
3Power
If a thick high-voltage electric cable is used to connect battery groups, then sufficient current can be transmitted, but the flexibility of the cable is low and it tends to project to undesired positions
Solution Approach 1:
The holding part acts as an intermediary that supports the thick, inflexible cable at a specific position. This allows the cable to maintain its thick cross-section for high current transmission while the holding part provides the necessary support to prevent the cable from projecting to undesired positions, effectively compensating for the low flexibility.
Data Source
AI summary
A wiring module configured to connect a power storage element group including power storage elements to external member includes: a connection member that connects electrodes of a pair of the power storage elements; an insulating protector that is attached to an electrode surface of the power storage element group and that houses the connection member; an electric cable that includes one end to be connected to a terminal electrode of the power storage element group and another end to be connected to the external member, and that is folded back from the one end to the other end; and a holding part that is provided to the insulating protector, and is configured to hold the electric cable.