Wire Harness Busbar Terminal Structure for Vibration-Stable Sensing
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Solution Overview
Problem
Existing connectors used for connecting wire harnesses and busbars in power batteries are prone to loosening during vehicle vibrations, leading to increased internal resistance and acquisition failures due to repeated insertion and extraction, affecting data stability and productivity.
Innovation Solution
A connecting terminal for acquisition wire harness with an intermediate connecting portion, wire harness connecting portion, and busbar connecting portion, which is clamped and welded to an accommodating portion on the busbar, ensuring a stable connection that resists vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flag-shaped connector is used for connection between wire harness and busbar, then the connection structure is simple and easy to install, but the connector is easily loosened during vehicle vibration, leading to increased contact internal resistance and acquisition failures
Solution Approach 1:
The connecting terminal is divided into three distinct portions: an intermediate connecting portion, a wire harness connecting portion, and a busbar connecting portion. Each portion serves a specific function and can be optimized independently, while the fixed connection between portions ensures overall structural stability during vibration.
Solution Approach 2:
The patent combines the functions of connection, fixation, and electrical conduction into a single integrated connecting terminal structure. The terminal merges the wire harness connection and busbar connection into one component, eliminating the need for separate flag-shaped connectors and reducing assembly steps.
2Reliability
If repeated insertion and extraction of the flag-shaped connector is performed, then loose connections can be corrected, but too many times of pulling out and inserting cause permanent looseness and acquisition abnormalities
Solution Approach 1:
The connecting terminal is pre-designed with an optimal connection structure that prevents loosening from occurring in the first place. The fixed connection between the intermediate connecting portion and the busbar connecting portion is established during manufacturing, eliminating the need for field adjustments or reinsertion operations.
3Reliability
If a stable connection structure is implemented to prevent loosening during vibration, then acquisition reliability improves, but the device complexity increases
Solution Approach 1:
The connecting terminal applies local quality by providing different structural characteristics in different portions: the intermediate connecting portion has a fixed rigid connection for stability, the wire harness connecting portion has pressing capability for secure attachment, and the busbar connecting portion has clamping function. Each portion is optimized for its specific function while maintaining overall simplicity.
Data Source
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AI summary
The present application discloses a connecting terminal for acquisition wire harness, a battery module, and a power-consuming device. The connecting terminal for acquisition wire harness includes an intermediate connecting portion, a wire harness connecting portion, and a busbar connecting portion. The intermediate connecting portion is fixedly connected to the wire harness connecting portion and the busbar connecting portion. The wire harness connecting portion and the acquisition wire harness are pressed and fixed. The busbar connecting portion is clampable to an accommodating portion preset on a busbar.