Insulated Bus Bar for Front Access Battery Rack
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Solution Overview
Problem
Current battery rack systems face safety and efficiency issues due to exposed bus bar terminals, which require side or rear access connections, making them difficult to access and less efficient compared to front access systems.
Innovation Solution
An all front access battery rack system utilizing insulated bus bar connections that electrically couple controller and battery rack modules, ensuring safe and efficient power distribution with conductive and insulative materials, and optional insulation covers for added safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable connections with exposed bus bar terminals are used, then battery rack modules can be interconnected, but safety hazards increase due to exposed terminals requiring insulation covers
Solution Approach 1:
The bus bar is merged with the insulative material to form an integrated insulated bus bar assembly. The conductive bus bar and insulative material are combined into a single component structure, eliminating the need for separate insulation covers and reducing the number of parts while maintaining safety
Solution Approach 2:
The insulated bus bar utilizes composite materials by combining conductive material (for electrical conduction) with insulative material (for safety isolation). This composite structure allows the same component to provide both electrical connectivity and safety insulation functions
2Ease of operation
If side or rear access terminals are used, then safety hazards are reduced, but accessibility and efficiency decrease
Solution Approach 1:
The bus bar terminal and insulation are merged into a single insulated bus bar assembly, allowing front access terminals to be both accessible and safe simultaneously, eliminating the need to choose between accessibility and safety
3Reliability
If insulated bus bar connections are used, then safety is improved by eliminating exposed terminals, but manufacturing complexity increases
Solution Approach 1:
By merging the bus bar and insulation into a single pre-assembled unit, the manufacturing process is actually simplified compared to handling separate components. The integrated assembly reduces the number of assembly steps and potential errors during installation
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
The system provides a safer and more efficient method for connecting battery rack modules, allowing for easier setup and installation, while ensuring complete insulation and reduced exposure risks during operation.
Implementation Method 1
an insulative material electrically insulating the conductive material between the conductive connectors
Data Source
AI summary
In accordance with presently disclosed embodiments, an all front access battery rack system using insulated bus bars is provided. In one embodiment, a battery rack system may comprise: a controller rack module aligned on a rack; a battery rack module aligned on the rack; first and second insulated bus bars aligned perpendicularly to and electrically coupling the controller rack module with positive and negative terminals of the battery rack module along a front side of the rack, wherein each insulated bus bar comprises: a conductive material comprising conductive connector ends operable to electrically engage with the controller rack module and the battery rack module; and an insulative material electrically insulating the conductive material between the conductive connectors.