Voltage Sensing Assembly Groove Mounting for Battery Modules
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Solution Overview
Problem
The existing battery module assembly process is complex due to the need for multiple members for mechanical fastening and electrical connection, which complicates assembly, increases size, and poses risks of short circuits, especially under impact or vibration, necessitating a compact and stable voltage sensing solution.
Innovation Solution
A voltage sensing assembly with conductive sensing parts mounted in mounting grooves of a block case, allowing for simplified assembly and stable voltage sensing, featuring a modular structure that can be easily extended and maintained, with receptacle-type connections to maintain electrical contact under external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple members for mechanical fastening and electrical connection are used, then reliable electrical connection is achieved, but assembly process becomes complex and size increases
Solution Approach 1:
The patent combines mechanical fastening and electrical connection functions into a single integrated member. The sensing assembly includes a housing that mechanically mounts to the battery module while simultaneously providing electrical contact through integrated conductive elements, eliminating the need for separate fastening and electrical connection components.
Solution Approach 2:
The sensing assembly members are designed to perform multiple functions simultaneously. The housing serves both as a mechanical mounting structure and as an electrical conductor, while the sensing elements provide both structural support and voltage detection capabilities, reducing the total number of components needed.
2Reliability
If multiple members for mechanical fastening and electrical connection are used, then stable connection is achieved, but assembly size increases
Solution Approach 1:
The patent merges mechanical fastening and electrical connection into unified components. The housing integrates both structural support and electrical conductivity, and the sensing elements combine mounting functions with sensing capabilities, thereby reducing the overall volume required for connection mechanisms.
Solution Approach 2:
The sensing elements are nested within the housing structure, which itself is integrated into the battery module framework. This nesting arrangement allows multiple functions to be contained within compact, space-efficient configurations, minimizing the overall volume occupied by connection mechanisms.
3Reliability
If complex fastening and connection members are used, then electrical connection is reliable, but manufacturing space and cost increase
Solution Approach 1:
The patent combines mechanical fastening and electrical connection functions into single integrated members, reducing the number of parts that need to be manufactured and assembled. This integration simplifies the manufacturing process while maintaining reliable electrical connections.
Solution Approach 2:
The sensing assembly is divided into modular components (housing, sensing elements, connectors) that can be manufactured separately and then easily assembled. This segmentation allows for simplified manufacturing of individual components while maintaining the reliability of the complete assembly.
Data Source
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AI summary
Disclosed herein is a voltage sensing assembly to detect voltages of battery cells having electrode terminals formed at an upper end or a lower end thereof in a state in which the voltage sensing assembly is mounted to a battery module, the voltage sensing assembly including (a) a block case, formed of an electrically insulative material, mounted to a front or rear of the battery module corresponding to electrode terminal connection parts of the battery cells, (b) conductive sensing parts connected to voltage sensing terminals located at one-side ends of bus bars electrically connected to the electrode terminal connection parts of the battery cells, and (c) a connector to transmit voltages sensed by the conductive sensing parts to a controller, wherein the block case includes mounting grooves, opened to a front, formed at positions of the block case corresponding to the voltage sensing terminals of the bus bars such that the conductive sensing parts are mounted in the mounting grooves, and the conductive sensing parts are connected to the voltage sensing terminals of the bus bars in a state in which the conductive sensing parts are mounted in the mounting grooves of the block case.