Segmented Cover Member Absorbing Bus Bar Tolerance
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Solution Overview
Problem
The increased number of batteries in a battery assembly leads to larger cumulative tolerance, causing the cover member to be difficult to attach due to variations in the length of the bus bar module, resulting in dislocation of locking claws and reduced workability.
Innovation Solution
A cover member with positioning projections and elastically deforming portions that allow for movement and locking, absorbing tolerance variations without a complex structure, reducing the number of elastically deforming portions and simplifying the design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of batteries is increased to increase voltage, then the power output is improved, but the cumulative tolerance increases causing the cover member to be difficult to attach
Solution Approach 1:
The cover member is divided into multiple cover portions (first cover portion, second cover portion, etc.) that can independently move relative to each other. This segmentation allows each cover portion to accommodate local variations in the bus bar module length caused by cumulative tolerance, while maintaining overall coverage and protection functionality.
Solution Approach 2:
The cover portions are designed to be movable rather than fixed, connected through elastically deforming portions that allow dynamic adjustment. This enables the cover member to adapt to length variations in the bus bar module by allowing the cover portions to shift position, thereby maintaining proper alignment with locking projections despite manufacturing tolerances.
2Adaptability or versatility
If elastic portions are added to absorb tolerance, then the attachment adaptability is improved, but the device complexity increases
Solution Approach 1:
The elastically deforming portions are integrated directly into the cover member structure itself, merging the elastic absorption function with the cover portions. This eliminates the need for separate elastic components or mechanisms, reducing overall device complexity while maintaining the ability to absorb tolerance variations.
Solution Approach 2:
The cover portions utilize elastic deformation of the material to change their shape and position parameters dynamically. By changing the physical state (deformation) rather than adding mechanical adjustment mechanisms, the system achieves adaptability without increasing structural complexity.
3Reliability
If the locking claws are dislocated due to length variation, then the attachment reliability deteriorates, but the workability is reduced
Solution Approach 1:
By dividing the cover member into multiple movable cover portions, the system ensures that even if some locking claws experience dislocation due to tolerance accumulation, other cover portions can still achieve proper locking. This segmentation distributes the locking function across multiple independent units, maintaining overall attachment reliability.
Solution Approach 2:
The movable cover portions can dynamically adjust their positions to compensate for dislocation of locking claws. This dynamic adjustment capability allows the system to maintain reliable locking engagement despite variations in bus bar module length, preserving both reliability and workability.
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
The cover member can be easily attached to the bus bar module with a large cumulative tolerance, improving workability and reducing production costs while downsizing the power source.
Implementation Method 1
elastically deforming portions which movably connect the cover portions adjacent to each other
Data Source
AI summary
A cover member is attached to a bus bar module. The bus bar module includes: a plurality of bus bars respectively connecting batteries adjacent to each other of a battery assembly composed of a plurality of batteries overlapped with each other; a main body to which the bus bars are attached, and overlapped with the battery assembly; a plurality of positioning projections and a plurality of locking portions provided on the main body. The cover member includes: a plurality of cover portions arranged in parallel to an overlapping direction X of the batteries, and covering the bus bars; and a plurality of elastically deforming portions movably connecting the cover portions adjacent to each other. Each of the cover portions includes: a positioning hole into which the positioning projection is inserted; and a lock receiving portion with which the locking portion is locked.