Electric Junction Box Placement in Battery Pack
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Solution Overview
Problem
Conventional electric junction box arrangements in battery packs of electric vehicles are prone to damage in collisions, leading to potential short circuits and deterioration of collision strength due to multiple notched holes for wire guidance, which complicates connection and protection work.
Innovation Solution
The electric junction box is positioned on the side of the battery pack opposite to the collision direction, with concentrated wire connection parts on the wall, guiding wires out along this wall to prevent direct damage and reduce the need for multiple notched holes, thus enhancing safety and workability while minimizing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electric junction box is placed in the battery pack with multiple electric wires guided out in different directions, then the electrical connection functionality is achieved, but the collision strength of the battery pack deteriorates due to multiple notched holes
Solution Approach 1:
Multiple electric wires are bundled together into a single harness that exits the battery pack through one notched hole rather than multiple separate holes, thereby maintaining electrical connection functionality while preserving the structural strength of the battery pack
2Adaptability or versatility
If multiple electric wires are guided out in different directions from the electric junction box, then the required electrical connections are established, but the connection work requires a lot of time due to multiple connectors and terminals
Solution Approach 1:
Multiple electric wires are consolidated into a single harness with bundled connectors, reducing the number of individual connection operations required and significantly decreasing the time needed for connection work while maintaining all necessary electrical connections
3Reliability
If each electric wire is protected with a separate vinyl tube, then the electric wires are protected from damage, but the mounting of protection tubes requires a lot of time
Solution Approach 1:
Multiple electric wires are bundled together into a single harness that is protected by a single outer sheath or casing, providing comprehensive protection for all wires simultaneously and reducing the mounting time from multiple individual tube installations to one unified protection structure
4Volume of moving object
If the electric junction box is arranged on the collision side of the battery pack, then the space utilization is optimized, but the electric junction box is affected by great damage in collisions leading to potential short circuits
Solution Approach 1:
The electric junction box is extracted from the battery pack and positioned in a separate location away from the collision-prone area, eliminating it from the high-risk zone while maintaining its electrical connection functions through the bundled wire harness
Data Source
AI summary
An arrangement structure of an electric junction box is provided, by which damage of the electric junction box in the event of a collision of a vehicle can be reduced and a plurality of electric wires can be easily connected to the electric junction box with good workability. The arrangement structure includes: a high voltage battery; a battery pack for receiving the battery, the battery pack being mounted on a vehicle; and an electric junction box arranged in the battery pack, the electric junction box being connected to the battery, wherein on the assumption that a collision takes place on the battery pack-mounting side of the vehicle, the electric junction box is arranged on the side of a wall of the battery pack, the wall being situated on the side opposite to the collision side of the vehicle.