Voltage Sensing Assembly Bus Bar Integration
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Solution Overview
Problem
The existing voltage sensing assemblies for battery modules are complex to assemble, prone to short circuits due to numerous wires, and suffer from increased size and contact resistance issues, making them unreliable and inefficient for high-power applications like electric vehicles.
Innovation Solution
A compact voltage sensing assembly where wires are directly connected to bus bars using a fastening member within a block case, eliminating the need for additional assembly structures and allowing for a simple, reliable voltage measurement with reduced parts and improved maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If voltage sensors are connected to battery cells using many wires and additional assembly parts, then voltage sensing capability is achieved, but assembly process becomes complicated and short circuit risk increases
Solution Approach 1:
The patent combines the voltage sensing function directly into the bus bar structure by integrally forming voltage sensing terminals at the ends of bus bars. This merging eliminates the need for separate voltage sensors and multiple connecting wires, thereby simplifying the assembly process while maintaining reliable voltage sensing capability across all battery cells.
Solution Approach 2:
The bus bar is designed to serve multiple functions simultaneously: it provides electrical connection between battery cells and integrates voltage sensing terminals for monitoring. This multi-functionality eliminates the need for dedicated separate components for voltage sensing, reducing assembly complexity while ensuring reliable voltage detection.
2Reliability
If additional assembly parts such as receptacle terminals are used for voltage sensing, then voltage sensing is achieved, but contact resistance increases and sensing accuracy deteriorates
Solution Approach 1:
The voltage sensing terminals are integrally formed with the bus bar as a single piece, eliminating additional assembly parts and contact interfaces. This direct integration removes contact resistance issues that would otherwise occur at connection points between separate components, thereby improving voltage sensing accuracy and reliability.
3Ease of manufacture
If a large number of members are used for mechanical coupling and electrical connection between battery cells, then battery module is assembled, but assembly process becomes very complicated and system size increases
Solution Approach 1:
The bus bar structure is designed to provide both mechanical support and electrical connection functions in a single component. By integrating the voltage sensing terminals directly into the bus bar, the patent eliminates the need for separate mounting brackets, receptacle terminals, and additional fastening hardware, thereby simplifying the assembly process and reducing the overall battery module size.
4Reliability
If separate voltage sensing assembly is used, then voltage sensing reliability is improved, but assembly process becomes more complex
Solution Approach 1:
The voltage sensing functionality is merged into the bus bar structure itself through integral formation of sensing terminals. This integration allows voltage sensing to be implemented without adding separate assembly steps or components, thereby maintaining high assembly productivity while achieving reliable voltage sensing across all battery cells.
Data Source
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AI summary
Disclosed is a voltage sensing assembly for sensing voltage of battery cells, each having electrode terminals formed at an upper or 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 insulating material, the block case being mounted, horizontally within a space between electrode terminal connection parts of the battery cells, to the front or rear of the battery module, (b) wires connected respectively to voltage sensing terminals, each of the voltage sensing terminals being integrally formed at an upper or lower end of a corresponding one of bus bars electrically connected to the electrode terminal connection parts of the battery cells, and (c) a connector that transmits detected voltages of the wires to a controller, wherein the block case includes a fastening member that protrudes forward from the block case to securely fix the wires, and the wires are connected to the voltage sensing terminals of the bus bars in a state in which the wires are mounted to the fastening member of the block case.