Wiring Module Locking Mechanism for Battery Pack Tolerance
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Solution Overview
Problem
Existing wiring modules for battery packs in electric vehicles require a locking mechanism that allows for visual verification of the locked state without tilting the module, as the locking position changes due to tolerance issues, and current solutions do not adequately prevent foreign matter intrusion.
Innovation Solution
A wiring module design featuring a cover with a lock-receiving portion on its edge, allowing the locking portion of the resin protector to project in the same direction as the electrode terminals, enabling easy visual verification of the locked state and preventing foreign matter intrusion by eliminating the need for locking holes within the cover's edge portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the locking position is adjusted to accommodate tolerance variations, then the adaptability improves, but the ease of visually checking the locked state deteriorates
Solution Approach 1:
The locking portion is designed to extend in the electrode terminal connection direction (length dimension) rather than only in the thickness direction, creating a linear locking structure that accommodates tolerance variations along its length while maintaining visual checkability from the side
Solution Approach 2:
The locking portion acts as an intermediary element that bridges the cover and resin protector, providing both tolerance absorption through its extended structure and visual indication of the locked state through its position relative to the cover edge
2Adaptability or versatility
If the locking portion extends along the arrangement direction to absorb tolerance, then the adaptability improves, but the device complexity increases
Solution Approach 1:
The locking portion is segmented into multiple locking positions along its length, allowing it to engage with the cover at different positions to accommodate tolerance variations without requiring a complex adjustable mechanism
Solution Approach 2:
The locking portion serves multiple functions: it provides tolerance absorption through its extended structure, enables visual verification of the locked state, and maintains structural simplicity by using a single continuous element rather than multiple adjustable components
3Adaptability or versatility
If locking holes are provided within the cover's edge portion, then the locking mechanism becomes more flexible, but foreign matter intrusion increases
Solution Approach 1:
The locking function is extracted from the cover's interior by positioning the lock-receiving portion on the cover's edge, eliminating the need for internal locking holes that would create pathways for foreign matter intrusion
Solution Approach 2:
The lock-receiving portion is localized to the cover's edge region, creating a dedicated locking interface that maintains the cover's integrity in the interior region and prevents foreign matter intrusion while providing flexible locking capability at the edge
Data Source
AI summary
A wiring module includes multiple bus bars, a resin protector that has one or more holding portions that hold the bus bars and is provided with a tolerance absorbing portion that absorbs tolerance in the arrangement direction of power storage elements, and a cover that is attached to the resin protector and holds all of the holding portions. The resin protector is provided with a locking portion that locks the cover, the locking portion projecting in a direction identical to the projecting direction of electrode terminals and extending along the arrangement direction of the power storage elements. The cover is provided with a lock-receiving portion that is locked to the locking portion. The locking portion and the lock-receiving portion are locked in a manner of enabling relative movement along the arrangement direction of the power storage elements at an edge portion of the cover that extends in the arrangement direction of the power storage elements.