Tapered Lead Guide Assembly for Battery BMS Connector Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lead acid battery systems lack effective methods for monitoring battery parameters such as cell health and predicting failure, and close proximity of components can lead to damage and system inoperability.
Innovation Solution
A smart battery system with lead guides and a battery management system (BMS) that includes lead connections, thermal pads, and a PCB mount temperature sensor for monitoring cell parameters, using a lead guide with tapered openings to facilitate assembly and reduce damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If components are placed in close proximity and in contact to monitor battery parameters, then monitoring capability is improved, but risk of component damage increases
Solution Approach 1:
The patent introduces a lead guide as an intermediary component between the BMS connector and the battery cell leads. This lead guide provides a protective channel that guides the leads during assembly while preventing direct contact between components that could cause damage. The lead guide acts as a mediator that enables the monitoring function while protecting against the harmful effect of component damage.
Solution Approach 2:
The lead guide is designed with a tapered opening that provides gradual guidance and protection before the leads make final contact with the BMS connector. This tapered structure cushions the leads during insertion, preventing sudden impacts or misalignments that could cause damage. The protective channel is established beforehand to prevent potential damage before it occurs.
2Measurement precision
If leads are connected directly to battery cells for parameter sensing, then measurement capability is improved, but assembly difficulty increases
Solution Approach 1:
The lead guide serves as a mediator that simplifies the assembly process by providing a pre-formed channel for lead insertion. Instead of requiring precise direct alignment between leads and BMS connectors, the lead guide mediates this connection by providing a tapered opening that guides the leads into proper position, thereby reducing assembly difficulty while maintaining measurement capability.
Solution Approach 2:
The lead guide features a tapered opening with varying diameter along its length. This parameter change in the opening geometry allows easier insertion at the wider end and precise positioning at the narrower end, transforming the assembly process from a difficult precise alignment task to a simpler insertion task that self-aligns during the process.
3Measurement precision
If multiple leads are connected to multiple battery cells for comprehensive monitoring, then monitoring coverage is improved, but system complexity increases
Solution Approach 1:
The lead guide is designed as a universal component that can accommodate multiple leads simultaneously through its multiple openings. Each opening follows the same tapered design pattern, allowing the single lead guide structure to serve multiple monitoring functions for different battery cells. This multi-functional design enables comprehensive monitoring coverage while avoiding the need for separate complex assembly procedures for each lead.
Solution Approach 2:
The patent merges multiple lead connection functions into a single lead guide component. Instead of having separate guiding structures for each lead, multiple leads are combined and guided through the unified lead guide structure with multiple openings. This merging reduces the number of separate components and simplifies the overall system complexity while maintaining the ability to monitor multiple battery cells.
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
Enables efficient monitoring of battery parameters and reduces the risk of component damage during assembly, allowing for improved battery performance and failure prediction.
Implementation Method 1
a thermal pad providing thermal conductor and electrical insulator to cast-on strap (COS) for battery cell temperature
Data Source
AI summary
A system for determining a battery cell parameter of one or more battery cells of a battery is described. The system includes a BMS which includes a plurality of electrical connection points and a lead guide with a plurality of openings. Each opening is arranged to receive and guide a corresponding BMS connector to a corresponding electrical connection point on the BMS. Each opening has a first portion with a first end and a second portion with a second end. The first end has a first diameter. A diameter of the first portion has a tapered diameter from the first end of the first portion to the second portion. The BMS also includes processing circuitry electrically coupled to one or more electrical connection points and configured to determine the battery cell parameter of the battery cell(s) at least via the corresponding electrical connection point.