Sliding Busbar Connection for Simpler Traction Battery Pack Assembly
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Solution Overview
Problem
Existing methods for electrically connecting a control module of a traction battery pack to busbars are complex and require multiple assembly steps, posing a risk of operator contact with the busbars during assembly.
Innovation Solution
A traction battery pack system where a control module assembly slidably receives busbars protruding from the battery array, allowing for electrical coupling by moving the control module linearly in a single direction, thereby simplifying assembly and protecting the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing methods for electrically connecting control module to busbars are used, then electrical connection is achieved, but assembly process becomes complex and requires multiple steps
Solution Approach 1:
The patent combines multiple assembly operations into a single sliding motion. The control module assembly simultaneously achieves mechanical mounting and electrical connection by sliding along the busbars, eliminating the need for separate mounting and wiring steps. This merging of functions directly reduces assembly complexity while maintaining manufacturing ease.
Solution Approach 2:
The control module assembly is designed with multi-functional capability: it serves as both the mechanical mount and the electrical connector. The single assembly component performs multiple functions (structural support, electrical conduction, and positioning), thereby simplifying the overall assembly process without requiring multiple specialized components or steps.
2Reliability
If existing connection methods are used, then electrical coupling is achieved, but operator may contact busbars during assembly
Solution Approach 1:
The busbars are pre-positioned and protrude from the battery array before the control module assembly is installed. This preliminary positioning allows the operator to simply slide the control module into place without needing to manually handle or position the busbars, thereby preventing operator contact with exposed conductive surfaces during the assembly process.
Solution Approach 2:
The sliding mechanism acts as an intermediary between the operator and the busbars. Instead of the operator directly manipulating the busbars for connection, the controlled sliding motion of the control module assembly serves as a mediating action that achieves electrical coupling without requiring direct operator contact with the conductive busbar surfaces.
3Productivity
If multiple assembly steps are required, then precise electrical connection can be achieved, but assembly time increases
Solution Approach 1:
The busbar connection system is segmented into discrete protruding sections that align with corresponding receptacles on the control module assembly. This segmentation allows for precise electrical connection through a single sliding motion, eliminating the need for multiple adjustment and connection steps, thereby reducing assembly time while maintaining connection precision.
Data Source
AI summary
A traction battery pack system includes one or more busbars protruding from a battery array of a traction battery pack, and a control module assembly that slidably receives the one or more busbars to electrically couple the control module assembly to the one or more busbars. The control module assembly can be a bussed electrical center.