Rotatable Crimp Plug Connector for Low-Resistance Battery BMS Assembly
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Solution Overview
Problem
High transfer resistances occur between connection cables and high-current plug-in connectors in battery management systems, particularly due to screw connections, which are undesirable and inefficient.
Innovation Solution
A high-current plug-in connector with a crimp contact that can rotate within the plug-in connector housing, allowing for a single, low transfer resistance crimp connection, and an anti-rotation device for secure positioning, enabling flexible customization and orientation without twisting the cable, suitable for high-current applications up to 400 A.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screw connection is used to connect the plug-in contact to the connection cable, then the connection can be securely fastened, but high transfer resistance occurs between the connection cable and the plug-in connector
Solution Approach 1:
The invention extracts the harmful intermediate element (screw connection) from the electrical contact path. By removing the screw connection and using only a direct crimp connection, the patent eliminates the additional transfer resistance that occurs at the screw interface while maintaining secure mechanical fastening through the crimp connection alone.
Solution Approach 2:
The plug-in contact is segmented into functionally independent parts: the crimp connection section for electrical and mechanical connection to the cable, and the retention mechanism for securing the contact in the housing. This segmentation allows the crimp connection to be optimized purely for electrical conductivity without the compromise of combining it with a screw connection.
2Stability of the object's composition
If the plug-in contact is fixed in a specific orientation in the housing, then the connection is stable, but the cable must be twisted or forced during mounting which increases mechanical resistance and complicates installation
Solution Approach 1:
The plug-in contact is designed with rotational freedom during the mounting process, allowing it to dynamically adjust its orientation as the cable is inserted. The retention mechanism only engages after insertion to fix the contact in its final position, providing stability only when needed and freedom during installation.
Solution Approach 2:
The crimp connection is pre-formed with sufficient mechanical strength and orientation flexibility before insertion. This preliminary preparation allows the contact to be inserted without pre-alignment requirements, and the retention mechanism then performs the preliminary action of securing the contact after insertion.
3Adaptability or versatility
If different types of contacts (screw and crimp) are used for different applications, then specific requirements can be met, but the device complexity and variety of components increases
Solution Approach 1:
The plug-in contact is designed as a universal component that combines both crimp connection and retention functions in a single element. This multi-functional design allows the same contact type to be used for all high-current applications, eliminating the need for separate screw contacts and crimp contacts while maintaining adaptability to different cable and housing configurations.
Data Source
AI summary
A flush-mounted plug connector is suitable for use in a battery management system. A plug connector housing has an assembly flange for assembling the plug on a housing wall of a housing, e.g. of the battery management system. A plug contact is integrated into the plug connector housing. The plug contact has a plug-in axis, a plug-in region, and a cable connection region. The cable connection region can be connected to the battery management system via a connection cable which is designed as a high-current cable. The cable connection region is designed as a crimp connection such that the plug contact is a crimp contact which is held in the plug connector housing in a rotatable manner about the plug-in axis at least during the assembly process, and after being assembled, the integrated crimp contact can be disassembled again by means of a disassembly tool.