Power Supply Device Bus Bar Positioning and Assembly
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Solution Overview
Problem
The assembly of power supply devices in hybrid motor vehicles and electric vehicles is complicated due to the need for precise attachment of connecting members to cell assemblies, which requires multiple steps and can lead to inaccuracies and stress on components.
Innovation Solution
A power supply device design that incorporates a positioning unit with protruding portions and a guide unit with contact pieces to ensure accurate alignment and attachment of connecting members to electrodes, along with elastically deformed portions to maintain horizontal contact and prevent inclination, and a measuring section for potential difference measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple connecting members are attached to the cell assembly using a plate with holes and nuts, then the cells can be connected in series, but the assembly work becomes complicated and time-consuming
Solution Approach 1:
The patent combines multiple connecting members into a single integrated plate structure with protruding portions that simultaneously connect multiple cells. Instead of attaching separate connecting members to each cell pair, the plate integrates multiple connection functions into one component, reducing the number of attachment operations and simplifying assembly while maintaining reliable electrical connections between cells
Solution Approach 2:
The plate is pre-formed with protruding portions that extend through holes before the cells are assembled. This preliminary preparation of the plate structure allows for easier alignment and attachment during assembly, as the connecting portions are already positioned and shaped to fit through the cell electrodes, reducing the complexity of the assembly process
2Strength
If nuts are screwed to electrodes to fix the cell assembly to the plate and connecting members, then the components are securely fixed, but the assembly process becomes more complicated
Solution Approach 1:
Instead of screwing nuts onto electrodes to attach the plate and connecting members, the patent inverts the approach by having the plate with protruding portions pass through the electrodes and be fixed from the opposite side or through interference fit. This reversal of the attachment method eliminates the need for multiple nut-screwing operations while maintaining secure fixing, thereby simplifying the assembly process without compromising fixing strength
3Productivity
If the plate and connecting members are attached without precise positioning, then the assembly is faster, but the attachment accuracy decreases leading to component stress and potential damage
Solution Approach 1:
The plate is designed with localized protruding portions at specific positions corresponding to the cell electrodes. These protruding portions provide precise local positioning and alignment features that ensure accurate attachment without requiring overall precise positioning of the entire plate. This localized quality approach maintains high attachment precision while allowing for faster assembly through self-alignment features
Data Source
AI summary
A power supply device, which is simply assembled and in which a cell assembly and a measuring section are freely inserted and detached, is provided. A power supply device 1 includes a cell assembly 2, a plurality of first bus bars 51, a plate 3 to which the plurality of bus bars 51 are attached. The plate is overlapped on the cell assembly 2. The cell assembly 2 has a plurality of cells 21 respectively including positive electrodes 23 at one ends and negative electrodes 24 at the other ends. The first bus bars 51 connect the positive electrodes 23 of the one cells 21 to the negative electrodes 24 of the other cells 21 of the cell assembly 2 which are mutually adjacent when the plate 3 is overlapped or overlaid on the cell assembly 2. The power supply device 1 includes a positioning unit 71 that relatively positions the cell assembly 2 to the plate 3 and a guide unit 72 that guides the plurality of first bus bars 51 to positions where the first bus bars 51 connect the respectively corresponding positive electrodes 23 to the negative electrodes 24 when the plate 3 is attached to the cell assembly 2.