Tiltable Bus Bar Assembly for Battery Module Cell Placement
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Solution Overview
Problem
The existing assembly processes for battery modules and packs are inefficient, which hinders productivity and market competitiveness as demand for high-capacity battery cells increases.
Innovation Solution
A battery module design featuring a base frame, cover frame, and a tiltable bus bar unit that pivots between two locations, allowing for improved assembly efficiency by preventing component interference and facilitating accurate placement of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plurality of battery cells are connected in series or parallel to configure a battery pack, then the output voltage and charge/discharge capacity can be adjusted to meet different requirements, but the assembling process becomes more complex and less efficient
Solution Approach 1:
The battery pack is divided into multiple battery modules, each module containing a specific number of battery cells connected in series. This segmentation allows flexible configuration of output voltage and capacity by selecting different modules, while each module can be assembled independently to improve overall assembly efficiency
Solution Approach 2:
The bus bar unit is designed with universal connection structures that can accommodate different battery cell configurations. The tiltable design and standardized connection interfaces enable the same bus bar unit to work with various module configurations, reducing the need for custom assembly procedures
2Ease of manufacture
If the bus bar unit is fixed in position, then the structure is simple and easy to manufacture, but it causes component interference and reduces assembly efficiency
Solution Approach 1:
The bus bar unit is designed to be tiltable rather than fixed, allowing it to change position during the assembly process. This dynamic design enables the bus bar unit to be positioned at an angled state during assembly to avoid interference with battery cells, then fixed in a horizontal position after assembly, thereby improving assembly efficiency without significantly complicating the structure
Solution Approach 2:
The bus bar unit is pre-positioned at an angled state before battery cell installation. This preliminary positioning action prevents interference with the battery cells during assembly, and the tiltable design allows this pre-positioning to be easily achieved and later adjusted to the final horizontal position
Data Source
AI summary
A battery module includes a plurality of battery cells, a base frame configured to support the plurality of battery cells, a cover frame coupled to the base frame to cover the plurality of battery cells, and a bus bar unit coupled to the cover frame in a tiltable manner so as to be pivotable between a first location fixed to the cover frame and a second location fixed to the base frame, where the first location is oriented at a predetermined angle relative to the second location.