Plugin Module for High-Voltage Motor Vehicle Battery Assembly
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Solution Overview
Problem
The assembly of high-voltage motor vehicle batteries is complex and hazardous, with a high potential for errors, and requires significant installation space and multiple components, leading to increased costs and reduced volumetric energy density.
Innovation Solution
A compact motor vehicle battery design featuring multiple battery modules with integrated voltage taps and bus connections, connected via a plugin module that generates high voltage in a single step, eliminating the need for hazardous assembly processes and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery modules are connected with high-voltage cabling during assembly, then the high voltage is achieved, but the assembly process becomes hazardous and life-threatening for technicians
Solution Approach 1:
The patent applies preliminary action by pre-assembling battery modules with integrated low-voltage connections and control circuits before final high-voltage assembly. The modules are prepared in advance with all necessary connections except the final high-voltage linkage, allowing safe handling during manufacturing and assembly phases before the hazardous high-voltage state is activated
Solution Approach 2:
The patent introduces an intermediary approach by using standardized module interfaces and connection protocols that mediate between individual battery modules and the final high-voltage system. This intermediary layer allows modules to be assembled and tested independently at low voltage before being integrated into the high-voltage configuration, reducing direct exposure to high-voltage hazards during assembly
2Device complexity
If multiple components including high-voltage cabling, battery modules, and control circuits are assembled, then the complete battery system is formed, but the installation space increases and volumetric energy density decreases
Solution Approach 1:
The patent merges multiple functions into integrated battery modules that combine electrochemical cells, control circuits, and connection terminals into unified compact units. This consolidation eliminates the need for separate cabling and mounting structures, significantly reducing the overall installation space while maintaining complete system functionality
Solution Approach 2:
The patent implements multi-functionality through universal module designs that perform multiple functions simultaneously - energy storage, voltage regulation, temperature monitoring, and communication - all within a single standardized module. This multi-functional approach eliminates the need for separate dedicated components for each function, optimizing space utilization
3Device complexity
If multiple components with different suppliers are managed, then the complete battery system is assembled, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent segments the battery system into standardized, independently manufacturable modules that can be produced by different suppliers using the same interface specifications. This segmentation allows parallel manufacturing by multiple vendors while ensuring compatibility through standardized connection protocols and physical interfaces, reducing overall manufacturing complexity and cost
4Power
If battery modules are connected in series to achieve high voltage, then the total voltage increases, but the assembly process requires complicated protective measures
Solution Approach 1:
The patent applies preliminary action by pre-configuring modules with integrated low-voltage control circuits and connections before final high-voltage series assembly. The control infrastructure is established in advance, allowing for safe commissioning and testing procedures that reduce the need for complex protective measures during the voltage-accumulation assembly process
Data Source
AI summary
A motor vehicle battery includes multiple battery modules arranged in a row adjacent each other, each said multiple battery modules comprising a plug connection, a voltage tap and a bus connection integrated in the plug connection, and a control circuit coupled with the bus connection, and multiple galvanic battery cells, each of said multiple galvanic battery cells being connected witch each other by the plug connection; and a connection device configured as a single plugin module and comprising a battery management system, wherein the connection device is plugged onto all plug connections of the multiple battery modules and connects the voltage taps of all battery modules with a high-voltage battery connection and connects the bus connections of all battery modules with the battery management system.