Service Plug Attachment Structure for Battery Modules
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Solution Overview
Problem
Existing structures for attaching service plugs to battery modules with series-connected batteries face challenges in workability due to direct attachment to receiving terminals, restricting the shape of the service plug and requiring specific installation positions, and lack consideration for the connection process between terminals and electrodes.
Innovation Solution
A structure featuring an insulating substrate with protrusions and ribs that abut against connection terminals to prevent simultaneous rotation and movement, improving the connection process by using nuts and electric wires connected to the terminals, and a detachable connector for the service plug, enhancing workability without requiring additional support for the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the service plug is directly attached to the receiving terminals of the battery module, then the connection is simple, but the battery module must be installed at a specific position and the shape of the service plug is restricted
Solution Approach 1:
The connection system is divided into three separate components: the battery module with receiving terminals, the service plug with connector, and electric wires connecting them. This segmentation allows each component to be independently designed and positioned, enabling the service plug to be located at convenient positions away from the battery module while maintaining electrical connection.
Solution Approach 2:
Electric wires serve as intermediaries between the receiving terminals on the battery module and the connector on the service plug. These wires transmit electrical signals and power while allowing physical separation and flexible positioning of the service plug, eliminating the constraint of direct attachment to the battery module.
2Ease of operation
If the terminal is connected to the electrode by bolting without restraint, then the connection process is simple, but the terminal rotates simultaneously with the nut making the connection difficult
Solution Approach 1:
The terminal structure includes an engagement portion that automatically engages with a corresponding portion on the nut or mounting surface. This self-engagement mechanism prevents the terminal from rotating simultaneously with the nut during tightening, eliminating the need for additional restraint operations while maintaining connection simplicity.
Solution Approach 2:
The engagement portion of the terminal is designed with an asymmetric shape that fits into a corresponding asymmetric feature on the nut or mounting surface. This asymmetric design allows the terminal to be restrained in the correct orientation during bolting, preventing simultaneous rotation while keeping the connection process straightforward.
Data Source
AI summary
A structure for attaching a service plug includes an insulating substrate that has openings facing electrodes of a pair of adjacent batteries among a plurality of batteries in a battery module, a pair of connection terminals that are respectively connected to electrodes of the pair of adjacent batteries through the insulating substrate by bolting with nuts, a pair of electric wires whose one ends are connected to the connection terminals respectively, and a connector that is connected to the other ends of the pair of electric wires, and detachably connected with the service plug. The insulating substrate has protrusions which are abutted against the connection terminals respectively, and regulate movement of the connection terminals which simultaneously rotate with rotation of the nuts respectively when being bolted with the nuts.