Electrical system

Abstract

Electrical system (10) comprising: a high-voltage bus (13); a rechargeable energy storage system (14), RESS (14), connected to the high voltage bus (13); a battery separation unit (15), BDU (25) having a high-voltage switching device (30) configured to switch in response to a low-voltage drive current (i 30 ) to thereby connect the RESS (14) to the high voltage bus (13); a high-voltage component (16) electrically connected to the high-voltage bus (13), the high-voltage component (16) having a removable cover (18) and defining an operating opening (19) at least partially spanned by the cover (18) when the cover (18) is in an installed position; a fastener (22) connecting the cover (18) to the high-voltage component (16) when the cover (18) is in the installed position; a low-voltage driver circuit (24) configured to supply the low-voltage drive current (i 30 ) to the high-voltage switching device (30) to thereby switch the high-voltage switching device (30) into a closed state; and an electrical terminal (20) having a plurality of connecting pieces (54, 56, 58) which together form an electrical connection or a switch (57) in the low-voltage driver circuit (24), wherein separation of the plurality of connecting pieces (54, 56, 58) from one another opens the electrical connection or the switch (57) to prevent the low-voltage drive current (i 30) reaches the high-voltage switching device (30), and thereby causing the high-voltage switching device (30) to transition from the closed to an open state; characterized in that the electrical connector (20) includes first, second, and third connectors (54, 56, 58) as the plurality of connectors (54, 56, 58), the third connector (58) being configured to firmly engage the high-voltage component (16), and the first and second connectors (54, 56) being configured to removably connect the low-voltage driver circuit (24) to each other and to the third connector (58) to close the low-voltage driver circuit (24) and also prevent physical intrusion and removal of the fastener (22).

Description

Introduction

[0001] An electrified vehicle powertrain, power plant, or other high-voltage system may include an electrical system with separate high-voltage and low-voltage buses. While "high voltage" and "low voltage" are relative terms, "low voltage" often encompasses a maximum voltage level of 12–15 volts, i.e., a reserve voltage, with the term "high voltage" describing voltage levels well above the reserve voltage levels. For example, an electrically powered vehicle propulsion system may have a maximum bus voltage of 60–300 volts, with certain battery packs having a voltage capacity of 500–800 volts.

[0002] Regardless of their voltage ratings, the high-voltage and low-voltage buses of a dual-bus electric system are each connected to a high-voltage rechargeable energy storage system (RESS), such as a lithium-ion or nickel-metal hydride battery pack and associated power electronics, and a lead-acid or other application-appropriate auxiliary battery pack. Strategically positioned high-current fuses and high-voltage switches on the high-voltage bus support voltage isolation in the event of a fault condition, with the switches also being opened during routine shutdown procedures. Fuses are replaceable circuit elements that permanently enter the open-circuit state in response to a battery pack threshold. Therefore, maintenance efforts may involve accessing a high-voltage component for fuse replacement.

[0003] Additionally, some electrical systems use a software-based process known as "high-voltage interlock" (HVIL) to monitor the high-voltage bus for attempted access, such as attempted maintenance of a high-voltage electrical component. Generally, the HVIL procedure involves closely monitoring a low-voltage HVIL circuit for electrical continuity. A low-voltage controller commands one or more high-voltage breakers in the RESS to open in response to the detection of a circuit discontinuity. Other approaches to reducing the risk of high-voltage exposure in a dual-bus electrical system include the use of a manual service disconnect (MSD), a large battery pack fuse that can be manually removed by maintenance personnel before accessing the high-voltage bus.The physical removal of an MSD introduces very high resistance into the high voltage bus circuit to effectively break the RESS into multiple low voltage battery sections, thereby reducing the maximum voltage on the high voltage bus.

[0004] DE 10 2008 021 542 A1, a generic document, describes a monitoring device for contact or access protection of a hybrid vehicle with a number of high-voltage components and an electronic control unit connected to a low-voltage on-board power supply battery, the power actuators of which are connected to a high-voltage battery via a circuit breaker and control at least one electric machine. The high-voltage components are monitored by means of a line loop and deactivated when the power loop is open. A magnetic field-sensitive sensor of a detachable contact connection of the electric machine or the electronic control unit is connected to the line loop, and a control module of the electronic control unit activates a discharge unit for the contact-safe discharge of an energy storage device depending on a sensor signal generated by the sensor when the contact connection is released.

[0005] DE 10 2011 004 355 A1 describes a module for power distribution in an electrically powered vehicle. The module comprises a housing with a main terminal for connecting a high-voltage power source and at least two output-side terminals for connecting electrical consumers of the electric vehicle, as well as electrical conductor structures for electrically connecting the output-side terminals to the main terminal.

[0006] DE 10 2011 004 625 A1 describes a protective device for an electrical connection of a low-voltage device for a vehicle. The protective device comprises a first cover with a first fastening device for fastening the first cover in a first covering position over the electrical connection in order to prevent access to the electrical connection. The device further comprises a second cover with a second fastening device for fastening the second cover in a second covering position over the first cover and a detection element that is coupled to the second cover and is designed to experience a change in state when the second cover is removed from the second covering position, wherein the detection element has an interface to a monitoring device for detecting the change in state of the detection element. Description of the invention

[0007] The invention is defined by the claims.

[0008] Disclosed herein is an electrical system that minimizes and potentially eliminates dependence on the aforementioned manual service disconnect device (MSD) and / or high-voltage interlock (HVIL) monitoring method. While such approaches effectively reduce exposure to high-voltage power in an electrified powertrain, certain performance benefits can be enjoyed by eliminating preprogrammed HVIL control logic or the packaging space and ground associated with an MSD. Furthermore, the internal fuse structure and external packaging configuration of the MSD tend to be highly application-specific. The disclosed approach is therefore intended to provide a simplified and robust connector-based alternative, referred to herein as a "high-voltage system interlock" (HVSL), that can be extended across a wide range of electrical systems.

[0009] An electrical system according to the invention includes a rechargeable energy storage system (RESS), a high-voltage bus, a high-voltage component, and a battery disconnect unit (BDU) with one or more high-voltage electrical switching devices, e.g., contactors, solid-state switches, or other suitable switching configurations. The BDU is positioned between the RESS and one or both busbars of the HV bus. The binary open / closed switching state of the high-voltage switches is determined by an energized state of the switching devices. A low-voltage drive current is passed to the high-voltage switching devices via a low-voltage driver circuit to energize the switching devices. The energized switching devices close in response to the low-voltage drive current, with the closed state electrically connecting the RESS to the high-voltage bus and the rest of the electrical system.Likewise, the RESS is electrically isolated from the electrical system when the high-voltage switches are open.

[0010] The BDU's high-voltage switches open automatically in response to an idle condition of the drive circuit, such that the low-voltage drive current is physically interrupted or interrupted. While a control-based switching signal can also command the high-voltage switching device(s) to open or close in some embodiments, interrupting the drive current alone will cause the RESS to be disconnected and the high-voltage bus to be deactivated. For example, if the high-voltage switches are implemented as optional solenoid-driven devices without a generated magnetic field, the contactors are unable to remain closed and thus spring open when the magnetic field decays.

[0011] The high-voltage component defines a service opening spanned by a removable cover and closed when the cover is in an installed position. One or more fasteners can securely connect the cover to the high-voltage component in the installed position.

[0012] The electrical terminal described herein comprises a plurality of connectors, i.e., at least two and optionally three or more parts. The connectors together form a low-voltage electrical switch within the drive circuit. Separation of the various connectors from one another opens the electrical switch, which in turn creates an open-circuit condition in the low-voltage drive circuit, opening the driven high-voltage switches. The electrical terminal thereby performs a high-voltage system lockout (HVSL) function within the disclosed electrical system. Closing the high-voltage switches may require termination of a high-voltage lockout security procedure, e.g., removal of a physical locking device such as a padlock.As a result, reconnecting the electrical connector alone is not sufficient to realize the high-voltage bus, requiring a control signal to close the high-voltage switches according to such a locking operation, as appreciated by one skilled in the art.

[0013] When the electrical connector is connected to the high-voltage component, the electrical connector directly blocks access to the removable cover. For example, the connector may overlap a peripheral edge of the cover. In some embodiments, fasteners are used to secure the cover to the high-voltage component. Removal of the connector in such an embodiment is required to fully expose one or more of the fasteners, thereby allowing a tool bit to connect to a fastener head for cover removal.

[0014] According to the invention, the electrical connector includes a first connector configured to firmly engage the high-voltage component, and second and third connectors connected to each other and to the first connector to close the low-voltage driver circuit. At the same time, the coupled first, second, and third connectors can prevent or block access to the fastener(s) that secure the cover.

[0015] In some embodiments, the low voltage driver circuit may be routed between the high voltage switches and the second and third portions of the electrical connector.

[0016] The high voltage bus in one exemplary embodiment has a minimum voltage level of 60 volts, while the low voltage driver circuit in one embodiment has a maximum voltage level of 12 - 15 volts, ie, a low voltage / reserve voltage.

[0017] Optionally, the peripheral edge of the cover may be rectangular. Fasteners in such an embodiment may be positioned to secure a corresponding corner of the cover. The second and third connectors may restrict access to, and thus prevent removal of, the fastener(s), for example, by overlapping at least one of the fasteners.

[0018] The high voltage component may be an auxiliary power module (APM), i.e., a DC-DC converter, or a climate control module (ACCM) in two non-limiting exemplary embodiments.

[0019] The first connector may include one or more push-in clip fasteners to firmly attach the first part to the high voltage component.

[0020] The low-voltage drive circuit may include a multi-conductor wire. The second or third connector may include a U-shaped shorting bar that closes the drive circuit across the multi-conductor wire when the second and third connectors are connected together.

[0021] The electrical system may include a controller, referred to herein as a battery system manager (BSM), and a multiphase electric machine connected to the high-voltage bus via an inverter module. The BSM may optionally be configured to automatically discharge the high-voltage bus via the electric motor's switching control in response to the opening of the high-voltage switches.

[0022] According to another exemplary configuration in which the electrical connection comprises the aforementioned first, second, and third connectors, the first connector has a fastening feature that firmly engages the high-voltage component. The second connector is removably connectable to the first connector. The third connector is removably connectable to the first and second connectors. The first, second, and third connectors together form an electrical switch in the drive circuit, such that separation of the connectors from one another opens the electrical switch, thereby causing the high-voltage switches to open.

[0023] The above summary is not intended to represent every possible embodiment or aspect of the present disclosure. Rather, the above summary is intended to exemplify some of the novel aspects and features disclosed herein. The above features and advantages, as well as other features and advantages of the present disclosure, will be readily apparent from the following detailed description of the illustrated embodiments and modes for carrying out the present disclosure, taken in conjunction with the accompanying drawings and the appended claims. Brief description of the drawings Fig. 1 is a schematic diagram of an exemplary electrical system including a rechargeable energy storage system (RESS), high-voltage and low-voltage buses, a high-voltage component, and a multi-part electrical connector providing a high-voltage blocking function, as described herein. Fig. 2 is a schematic diagram for part of the electrical system of Fig. 1. Fig. 3 is a schematic perspective view of an exemplary high voltage component with a removable cover and a multi-part electrical connector according to one possible embodiment. Fig. Figure 4 is a schematic cross-sectional side view of a multi-part electrical connector which may be used as an alternative to the illustrated embodiment Fig. 3 is usable.

[0024] Modifications and alternative forms are contemplated for the present disclosure, and representative embodiments are shown by way of example in the drawings and described in detail below. Inventive aspects of this disclosure are not limited to the particular forms of this disclosure. Rather, this disclosure is intended to cover modifications, equivalents, combinations, and alternatives falling within the scope of the disclosure as defined by the appended claims. Detailed description

[0025] Referring to the drawings, where like reference numbers refer to like components, Fig. 1 an electrical system 10. The electrical system 10, which may be used as part of an exemplary vehicle 12 as described herein, or as part of a power plant or other mobile or stationary device or system, provides a high voltage system lockout (HVSL) function that may obviate the use of a manual service disconnect (MSD) and / or high voltage interlock (HVIL) method as described above.

[0026] The electrical system 10 includes multiple voltage buses, including a high-voltage (HV) bus 13 connected to a rechargeable energy storage system (RESS) 14. The term "high voltage," as used herein, refers to voltage levels above 12-15 volts low-voltage / auxiliary voltage levels, e.g., 60-300 volts or higher. As used herein, the term "RESS" refers to a multi-cell rechargeable battery pack with a lithium-ion, nickel-metal hydride, or other application-appropriate battery chemistry, as well as associated power electronics required for the proper control and thermal regulation of such a battery pack.

[0027] A high-voltage component 16 is electrically connected to the RESS 14 via the HV bus 13 and has a removable cover 18, such as a rectangular plate. As described below with particular reference to the Fig. 2, Fig. 3 and Fig. 4, the high-voltage component 16 defines an operating opening 19 that is spanned and sealed by the cover 18 when the cover 18 is attached to the high-voltage component 16 in an installed position. One or more fasteners 22 may be used to securely connect the cover 18 to the high-voltage component 16. A low-voltage drive current (arrows i) flows within the electrical circuit 10. 30 ) is connected to and through an electrical terminal 20 positioned adjacent to the cover 18, wherein a multi-part construction of the electrical terminal 20 forms an electrical switch in a low voltage driver circuit 24 to perform the noted HVSL function.

[0028] The RESS 14 of Fig. 1 is connected to the HV bus 13 via a battery disconnect unit (BDU) 25. Briefly referring to Fig. 2, the BDU 25 includes a high-voltage switching device 30, e.g., an electromagnetically operated contactor, as in Fig. 2, a solid-state / semiconductor switch or other suitable switching device in other embodiments and may include one or more additional high-voltage switches 130 and / or 230 connected in conjunction with a pre-charge resistor R PC The exemplary switching devices 30, 130 and 230 are implemented as optional high-current electromagnetic relays that are configured to operate in response to receiving the low-voltage drive current (arrows i 30 ), optionally in conjunction with a control signal from the controller 50 for additional high voltage blocking protection to electrically connect the RESS 14 to the rest of the electrical system 10 of Fig. 1 to connect.

[0029] The low-voltage drive current (arrows i 30) via the driver circuit 24, e.g., to corresponding solenoid coils 30S, 130S and 230S of the respective high voltage switches 30, 130 and 230 in the non-limiting embodiment of Fig. 2. Passage of the drive current (arrows i 30 ) through the exemplary solenoid coils 30S, 130S, and 230S in this illustrative embodiment energizes the solenoid coils 30S, 130S, and 230S, as would be appreciated by one of ordinary skill in the art. Mechanical switching elements S1, S2, and S3 having binary open and closed switching states are transitioned to a closed state, e.g., by an electromagnetic field generated around the exemplary solenoid coils 30S, 130S, and 230S when the solenoid coils 30S, 130S, and 230S are energized in this manner.

[0030] A corresponding return spring 17, 170 and 270, which are respectively coupled to the switching elements S1, S2 and S3, enables the switching elements S1, S2 and S3 to open quickly when the drive current (arrows i) 30 ) is turned off and the electromagnetic field of the solenoid coils 30S, 130S, and 230S decays. In this context, the high-voltage switches 30, 130, and 230 are normally open devices. As a result, control signals from a controller are not required to confirm a change in the switching state of the switching devices 30, 130, and 230. Rather, the switching states change automatically via the field decay when the driver circuit 24 is opened by the operation of the electrical terminal 20.

[0031] In the exemplary embodiment of Fig. 2, the BDU 25 can also adjust the pre-charging resistor (R) PC ) in series with the switching element S2. Auxiliary battery 21, which is also Fig. 1 and is shown there as B AUX may be electrically connected to node N1. At node N1, the power from the auxiliary battery 21 is split to provide an uninterrupted control drive current (arrow i) 50 ) to a low-voltage control in the form of a battery system manager (BSM) 50 for supplying associated control functions and for establishing a separate current path for the passage of the drive current (arrow i 30 ) of the high voltage switches 30, 130 and 230 by the driver circuit 24. In the present disclosure, the drive current (arrow i 30 ) the electrical terminal 20, the electrical terminal 20 being constructed to form an electrical switch in the solenoid driver circuit 24, as mentioned above.

[0032] The BSM 50 from Fig. 1 may be embodied as one or more low-voltage digital computers, each comprising a processor (P), e.g. a microprocessor or a central processing unit, and a memory (M) (see Fig. 1) in the form of a read-only memory, a random access memory, an electrically programmable read-only memory, etc., a high-speed clock generator, an analog-to-digital and digital-to-analog circuit, an input / output circuit and devices, and suitable signal conditioning and buffer circuitry.

[0033] The functions of the BSM 50 may vary depending on the intended use, including the functions of the battery management system, e.g., monitoring and controlling the temperature, state of charge, voltage, and other performance characteristics of the RESS 14. As such, an auxiliary voltage supply is always maintained in the BSM 50 regardless of the open / closed state of the switch formed by the electrical connection 20. Using the split-power approach at node N1 of Fig. Figure 2 is a possible embodiment to ensure the continuity of the above-described control functions of the BSM 50, wherein the separate power supply to the BSM 50 in Fig. 1 as a dedicated voltage bus 124. Other approaches may be used, such as a dedicated connection to a low-voltage output of the high-voltage component 16 when the high-voltage component 16 is configured as a DC-to-DC converter or using a dedicated auxiliary power supply.

[0034] With further reference to Fig. 1, the electrical system 10 may, in some embodiments, include an inverter module (PIM) 28. The PIM 28 may be electrically connected to a multi-phase electric motor (M E ) 31, e.g. an electric traction motor, as shown or an electric generator in other embodiments, via an alternating current (V) WS ) Voltage bus 32. The electric machine 31, when switched on, outputs the motor torque (arrow T) M ) to an input element 35 of a gearbox (T) 36. Output torque (arrow T O) is then transmitted from an output shaft 37 of the transmission 36 to one or more drive axles 40 and finally to a set of road wheels 42 in the illustrated embodiment of the vehicle 12.

[0035] The PIM 28 includes a series of IGBTs or other application-suitable semiconductor switches 34, which are shown together and schematically for simplicity. The semiconductor switches 34 have corresponding on / off (conductive / non-conductive) switching states that are activated in response to switching control signals (arrow CC O ) from the BSM 50, as appreciated by one skilled in the art. The switching control signals (arrow CCo) can be used for power reversal or conversion as needed.

[0036] Since the remaining high voltage energy after opening the high voltage switches 30, 130 and 230 of Fig. 2 can be stored, e.g. in a capacitor bank (not shown) of the PIM 28 and / or HV component 16, the BSM 50 can be configured as an additional control action to automatically release the high voltage bus 13 of the stored energy via the transmission of the switching control signals (arrow CC O ) to the PIM 28 in response to the opening of the high-voltage switches 30, 130, and 230. That is, the RESS 14, which is separate from the high-voltage bus 13, energy captured in such a capacitor bank, and other circuit components may be dissipated through the windings of the electric machine 31 via the operation of the semiconductor switches 34. Such an approach may require a connection to the processor (P) of the BSM 50 from the solenoid drive circuit 24. Other control actions of the BSM 50 may be initiated in response to control input signals (arrow CC I), including, but not limited to, the ongoing torque or speed control of the electric machine 31 and / or the battery management functions, such as the state of charge of the RESS 14.

[0037] With reference to Fig. 3, the high-voltage component 16, which can be designed as an additional energy module in the form of a DC-DC voltage converter, a climate control module or another high-voltage component of the Fig. 1, the electrical system 10 includes a main surface 44 and side or side surfaces 46 with various control connections 45, e.g., additional electrical and / or fluid / coolant connections. Access into the high-voltage component 16 may be periodically required to replace internal fuses and / or perform other maintenance tasks. For this purpose, the high-voltage component 16 defines the service opening 19. The opening 19 may be spanned by the removable cover 18 when the cover 18 is in the illustrated installed position. One or more fasteners 22 securely connect the cover 18 to the high-voltage component 16 when in the installed position. The cover 18 may have a rectangular perimeter, as shown, with a respective fastener 22 positioned at each of the corresponding corners 18C of the cover 18.

[0038] The above-mentioned electrical terminal 20, which may have a center line 11 as shown, may receive and support a multi-wire conductor 24W or optionally an optional four-wire conductor (not shown) which forms the conductive path of the Fig. 1 and Fig. 2. That is, the drive current (arrows i 30 ) flows to and from the high voltage switches 30, 130 and 230 of Fig. 2 by the multi-core conductor 24W and the electrical terminal 20. The electrical terminal 20 includes the respective first, second and third connectors 54, 56 and 58 in the illustrated exemplary embodiment, wherein the third connector 58 in Fig. 4 and described below. The connecting pieces 54, 56 and 58 of the electrical connector 20 together form an electrical connection or switch 57 (see Fig. 4) in the low voltage driver circuit 24 of the Fig. 1 and Fig. 2.

[0039] The separation of the connecting pieces 54, 56 and 58, which may be enabled by a push-button lock 59, ultimately interrupts the solenoid drive current (arrow i 30 ) and causes the high voltage switches 30, 130 and 230 of Fig. 2, ie, forming an open-circuit state in the low-voltage driver circuit 24. The connectors 54 and 56 may be linearly movable relative to each other and in communication with the connector 58, e.g., as a sliding camshaft or other mating element for easy separation from and separation from the connector 58.

[0040] In addition, the first and second connecting pieces 54 and 56 of Fig. 3, when connected or coupled to each other and connected to the high-voltage component 16, may be configured to physically block and thus prevent access to one or more of the fasteners 22. In particular, the connector 54 and / or 56 may be integrally formed or connected to a locking portion 52 of the electrical terminal 20, wherein the locking portion 52 may be formed as a cantilevered arm or extension of the first connector 54. The locking portion 52 is disposed between one or more of the fasteners 22, and an operator attempts to insert a bit of a screwdriver or other tool into a head of the fasteners 22. In this way, the locking portion 52 and / or the first or second connecting portion 54 or 56 prevents access to the fastener(s) 22.In other embodiments, the locking portion 52 may overlap a part or all of the surface of the cover 18, e.g., a peripheral edge defining the outer boundary of the service opening 19, such that removal of the electrical connector 20 is required to remove the cover 18.

[0041] Fig. Figure 4 shows another possible embodiment of the electrical connector 20, showing the respective first, second, and third connectors 54, 56, and 58. The connector 58 in the illustrated embodiment is configured to firmly engage the high-voltage component 16. The connectors 54 and 56 are configured to be connected to the connector 58 and to each other to connect the solenoid valve circuit 24 of the Fig. 1 and Fig. 2. The connector 58 may include a fastener 60 configured to firmly engage the high-voltage component 16. In an exemplary embodiment, the fastener 60 may be one or more compressed or ribbed clip fasteners that are pushed through a mating bore 70 in the high-voltage component 16, e.g., in an outer panel 160 of a housing thereof. Protrusions 69 of the first and second connectors 54 and 56 may engage engagement recesses 65 in the third connector 58 and thereby clamp onto the third connector 58 when the electrical terminal 20 is assembled and mounted, as shown.The projections 69 are configured to fully engage the recesses 65 when the solenoid drive circuit 24 is closed, which can help ensure that the HVSL feature remains intact during subsequent HV maintenance events. As a variation, the recesses 65 can be integrated into the surface 44 and / or the plate 160, and another recess 65 can be integrated into the cover 18, with such an embodiment potentially eliminating the need for a third connector 58.

[0042] The above mentioned multi-core conductor 24W can be used to connect the Fig. 2 and Fig. 3 to form the driver circuit 24. The multi-core conductor 24W can be connected between corresponding high-voltage switches 30, 130 and 230, e.g., the solenoid valves 30S, 130S and 230S of Fig. 2 and the second and third connecting pieces 54 and 56 of the electrical terminal 20. The connecting pieces 54 and 56 may include a U-shaped shorting bar 53 that closes the low-voltage driver circuit 24, i.e., closes an open circuit gap in the multi-wire conductor 24W, when the second and third connecting pieces 54 and 56 are connected together. For example, distal ends 24E of the multi-wire conductor 24W may be plugged into mating receptacles defined by ends 53E of the U-shaped shorting bar 53, as shown.

[0043] As explained in detail above with reference to the Fig. 1 - 4, the separation of the first, second and third connectors 54, 56 and 58 from each other finally opens the switch 57 to create an open circuit in the low-voltage driver circuit 24. With an open circuit condition established in the drive circuit 24, the drive current (arrow i 30) the high voltage switches 30, 130 and 230 can be Fig. 2. Terminating the field generation in the exemplary electromagnetic-driven application thus causes the high-voltage switches 30, 130 and 230 to Fig. 2, which in turn opens the RESS 14 of Fig. 1 from the high-voltage component 16. By stopping the drive current (arrow i 30 ) in the driver circuit 24, the BSM 50 can trigger to automatically discharge the high voltage bus 13 as mentioned above.

Claims

[1] Electrical system (10) comprising: a high-voltage bus (13); a rechargeable energy storage system (14), RESS (14), connected to the high voltage bus (13); a battery separation unit (15), BDU (25) having a high-voltage switching device (30) configured to switch in response to a low-voltage drive current (i 30 ) to thereby connect the RESS (14) to the high voltage bus (13); a high-voltage component (16) electrically connected to the high-voltage bus (13), the high-voltage component (16) having a removable cover (18) and defining an operating opening (19) at least partially spanned by the cover (18) when the cover (18) is in an installed position; a fastener (22) connecting the cover (18) to the high-voltage component (16) when the cover (18) is in the installed position; a low-voltage driver circuit (24) configured to supply the low-voltage drive current (i 30 ) to the high-voltage switching device (30) to thereby switch the high-voltage switching device (30) into a closed state; and an electrical terminal (20) having a plurality of connecting pieces (54, 56, 58) which together form an electrical connection or a switch (57) in the low-voltage driver circuit (24), wherein separation of the plurality of connecting pieces (54, 56, 58) from one another opens the electrical connection or the switch (57) to prevent the low-voltage drive current (i 30) reaches the high-voltage switching device (30), and thereby causing the high-voltage switching device (30) to transition from the closed to an open state; characterized by , that the electrical connector (20) includes first, second, and third connectors (54, 56, 58) as the plurality of connectors (54, 56, 58), the third connector (58) being configured to firmly engage the high-voltage component (16), and the first and second connectors (54, 56) being configured to removably connect the low-voltage driver circuit (24) to each other and to the third connector (58) to close the low-voltage driver circuit (24) and also prevent physical intrusion and removal of the fastener (22). [2] The electrical system (10) of claim 1, wherein the high voltage switching device (30) is a solenoid-operated contactor and the low voltage driver circuit (24) is connected between a solenoid of the solenoid-operated contactor and the second connector (56) and third connector (58). [3] The electrical system (10) of claim 1, wherein the high voltage bus (13) has a minimum voltage level of 60 volts and the low voltage driver circuit (24) has a maximum voltage level of 15 volts. [4] The electrical system (10) of claim 1, wherein the cover (18) has a perimeter that is rectangular, and the fastener (22) includes a plurality of fasteners (22) each securing a corresponding corner (18C) of the cover (18), the first connector (54) and the second connector (56) being configured to prevent removal of the fastener (22) by blocking access to at least one of the fasteners (22). [5] The electrical system (10) of claim 1, wherein the high voltage component (16) is an auxiliary power module. [6] The electrical system (10) of claim 1, wherein the high voltage component (16) is a climate control module. [7] The electrical system (10) of claim 1, wherein the third connector (58) includes a folded or ribbed push-in clip fastener securing the third connector (58) to the high voltage component (16). [8] The electrical system (10) of claim 1, wherein the low voltage driver circuit (24) includes a multi-conductor wire (24W) and the first connector (54) or second connector (56) includes a U-shaped shorting bar that contacts the multi-conductor wire (24W) to close the low voltage driver circuit (24) when the first connector (54) and the second connector (56) are connected together. [9] The electrical system (10) of claim 1, further comprising a battery system manager (50), BSM (50), an inverter module (28), and a multi-phase electric motor (31) connected to the high-voltage bus (13) via the inverter module (28); wherein the BSM (50) is a controller configured to automatically discharge the high-voltage bus (13) via the transmission of switching control signals (CCo) to the inverter module (28) in response to the high-voltage switching device (30).

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