Overlapping Copper Bus Layout for Space-Saving Battery Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current energy storage battery systems face challenges with flexible cables that occupy more space and are difficult to install due to entanglement and the need for manual arrangement, especially in large-scale systems where thicker cables require more space and complex fixing methods.
Innovation Solution
The use of overlapping copper buses that can be configured to fit the available space, featuring grooves and fixing mechanisms for easy installation and reduced manual handling, with heat fusion techniques to secure the buses to the upper cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible cables are used to connect battery modules, then the cables can be easily routed and installed, but the cables occupy more space inside the casing and become entangled requiring manual arrangement
Solution Approach 1:
The copper bus is divided into multiple segments including a main body and multiple plate bodies. Each plate body can be independently positioned in grooves, allowing the bus to be segmented and arranged to fit the available space efficiently while maintaining electrical connectivity.
Solution Approach 2:
The copper bus structure transitions from a traditional linear cable arrangement to a three-dimensional overlapping configuration with plate bodies extending in multiple directions. This dimensional change allows the bus to utilize vertical and lateral space more effectively, reducing the overall space occupied while maintaining connectivity.
2Power
If thicker cables are used to accommodate larger currents in large-scale battery systems, then the current carrying capacity is improved, but the cables take up more space and require complex fixing methods
Solution Approach 1:
The copper bus is segmented into a main body and multiple plate bodies that can be distributed across grooves. This segmentation allows the current path to be distributed across multiple thinner conductive surfaces rather than requiring a single thick cable, reducing the space occupied while maintaining current carrying capacity.
Solution Approach 2:
The current conduction path transitions from a single thick-dimensional cable to a multi-dimensional plate structure. The plate bodies extend in lateral directions and overlap in three-dimensional space, allowing current to flow through multiple parallel paths that collectively handle large currents without requiring thick cables.
3Manufacturing precision
If manual arrangement of cables is performed to handle entanglement, then the installation quality is improved, but the assembly process time is increased
Solution Approach 1:
The copper bus plate bodies are pre-configured with specific shapes and dimensions that correspond to predetermined groove patterns on the upper cover. This preliminary configuration eliminates the need for manual arrangement during assembly, as the components naturally fit together in the correct positions, reducing assembly time while maintaining installation quality.
Solution Approach 2:
The overlapping copper bus structure with plate bodies in grooves is designed to self-align and self-position during assembly. The geometric constraints of the grooves and the shape of the plate bodies automatically guide the components into their correct positions without requiring manual intervention for arrangement, thereby reducing assembly time while ensuring proper installation quality.
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
This solution allows for efficient space utilization and simplifies the assembly process by eliminating the need for manual cable arrangement, reducing installation time and space requirements in large energy storage battery systems.
Implementation Method 1
the first side wall is in a molten state and the main body is pressurized, so that the barb part moves to the lower part, the outside of the barb part enters the first side wall, and the connecting part moves to the upper part; wherein, after completing heat fusion, the first side wall is cooled and solidified
Data Source
AI summary
An energy storage battery system with overlapping copper buses is provided, including a casing, a plurality of battery modules, an upper cover, and a plurality of copper buses. The casing has a positive electrode and a negative electrode. The battery modules are arranged in the casing. The upper cover is disposed in the casing and located above the battery modules. The copper buses are disposed on the upper cover and are electrically connected to the battery modules, the positive electrode and the negative electrode. As such, the copper buses can be arranged according to the shape of the space of the upper cover, thereby achieving the effect of saving space. Furthermore, the copper buses are easy to install on the upper cover and do not require manual arrangement of cables, thereby effectively reducing the assembly process and man-hours.