Stepped Vehicle Battery Casing Rigidity Design
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Solution Overview
Problem
Existing vehicle battery blocks face issues with casing deformation due to external forces and heat, inefficient terminal holder mechanisms, and component misassembly challenges due to similar appearances.
Innovation Solution
A battery block design featuring a stepped casing for increased rigidity, an inclined rib for precise terminal holder alignment, and distinct terminal seats to prevent misassembly, along with a locking system and wire locking mechanism for enhanced durability and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the casing is made of synthetic resin through injection molding, then the manufacturing cost and ease of manufacture are improved, but the strength and rigidity of the casing deteriorate, making it easily bent or deformed under external force and heat
Solution Approach 1:
The battery block combines synthetic resin casing with metal reinforcing ribs to create a composite structure. The resin provides ease of manufacture through injection molding while the metal ribs provide the necessary strength and rigidity to resist deformation under external forces and heat.
Solution Approach 2:
The casing is divided into multiple sections with reinforcing ribs integrated into the structure. These ribs segment the continuous resin material into reinforced zones that provide localized strength while maintaining the overall ease of manufacture through molded-in features.
2Reliability
If a holder is added to push the terminal lance, then the reliability of terminal connection is improved, but the device complexity increases due to additional components and assembly steps
Solution Approach 1:
The holder function is merged with the terminal lance structure itself. The lance includes integrated positioning features and elastic deformation capabilities that combine the holding and pushing functions into a single component, reducing overall device complexity while maintaining reliable electrical connections.
Solution Approach 2:
The terminal lance is designed with elastic properties that allow it to self-adjust and maintain contact pressure without requiring an external holder mechanism. The lance's own elasticity provides the necessary pushing force to maintain reliable connections.
3Adaptability or versatility
If multiple components with similar appearance are mounted in the battery block, then the functionality and adaptability are improved, but the ease of operation deteriorates as workers have difficulty recognizing assembly locations
Solution Approach 1:
Each component mounting location is given distinctive local characteristics through varying shapes, sizes, and geometric features of the recesses. This allows workers to easily identify correct assembly locations by matching component shapes to corresponding recess shapes, improving ease of operation while maintaining the ability to mount multiple different components.
Solution Approach 2:
The battery block features asymmetrically shaped recesses and mounting locations that prevent incorrect component installation. Each component has a corresponding asymmetric recess that only accepts the correct component orientation, providing intuitive visual and physical guidance for assembly.
4Ease of operation
If the terminal holder is designed with a gap to reduce insertion force, then the ease of operation is improved, but the reliability deteriorates as the holder cannot efficiently fasten the lance
Solution Approach 1:
The terminal holder and lance interface is designed with dynamic elastic deformation capabilities. The holder material or structure allows for controlled elastic deformation during insertion to reduce insertion force, then maintains sufficient clamping force in the assembled state to ensure reliable fastening of the lance.
Data Source
AI summary
Provided is a battery block for a vehicle. The battery block includes: a main body (10) provided with an installation space (11′) therein for receiving components; and an upper casing (50) mounted to an upper part of the main body (10), an inside of the upper casing mounted to an upper part of a vehicle battery (100), wherein the main body (10) is provided with at least one step (11) along a longitudinal direction of the main body (10) such that heights of opposite sides of the step (11) are different from each other. The main body (10) has a relatively short section with a same height, and therefore rigidity thereof is increased, whereby bending or torsion of the casing is reduced. Thus, durability of the battery block is improved.