Ribbed Busbar Layout for Precise Battery Tab Welding
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Solution Overview
Problem
Existing busbar designs for electrified vehicle traction battery packs face challenges in properly positioning and aligning tab terminals during assembly and welding, leading to potential errors and inconsistencies in electrical connections.
Innovation Solution
The proposed traction battery pack incorporates a busbar with a rib configuration, such as an L-bend or T-rib, that facilitates the alignment of tab terminals from neighboring battery cells. The rib is positioned between openings in the busbar, allowing tab terminals to extend through and be securely welded to the rib, ensuring accurate and consistent connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional busbar designs without ribs are used, then the structure is simpler, but the alignment and welding precision of tab terminals deteriorates
Solution Approach 1:
The busbar is segmented by adding ribs that divide the connection area into distinct zones. Each rib creates separate positioning features for tab terminals, allowing precise alignment without requiring complex overall busbar geometry. The rib structure segments the connection surface to provide dedicated alignment references.
Solution Approach 2:
The rib acts as an intermediary element between the busbar body and the tab terminals. It provides an intermediate positioning surface that facilitates accurate alignment and welding, mediating the connection between the main busbar structure and the battery cell tabs without requiring direct complex interaction between the terminals and the busbar body.
2Manufacturing precision
If rib features are added to the busbar, then the alignment and welding of tab terminals is improved, but the manufacturing complexity increases
Solution Approach 1:
The ribs are pre-formed on the busbar during the busbar manufacturing process itself, rather than being added as separate components later. This preliminary action of creating positioning features during primary manufacturing reduces overall assembly complexity and maintains manufacturing ease while achieving precise alignment and welding capabilities.
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 design enhances the alignment and welding of tab terminals, reducing errors and improving the reliability of electrical connections within the traction battery pack, thereby ensuring consistent voltage and power delivery for vehicle propulsion.
Implementation Method 1
A weld secures the first tab terminal to the first side of the rib and secures the second tab terminal to the second side of the rib
Data Source
AI summary
Busbars are provided for electrically connecting battery cells within a traction battery pack. An exemplary busbar may include features for locating and positioning tab terminals of neighboring battery cells. For example, the busbar may include openings and ribs that separate adjacent openings. A first tab terminal of a first battery cell may be positioned for connection at a first side of the rib, and a second tab terminal of a second battery cell may be positioned for connection at a second side of the rib. The first and second tab terminals may each be secured (e.g., welded) to the rib.