Battery Safety Disconnect Shaft for High-Voltage Maintenance Isolation
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Solution Overview
Problem
Conventional methods for disabling high voltage batteries to ensure safety during maintenance introduce complexity, weight, and reliability issues by using external shunts or knife switches, increasing manufacturing and installation costs.
Innovation Solution
A battery safety disconnect system with a single interconnected shaft having conductive and non-conductive sections, allowing for a compact and reliable design that reduces battery voltage by moving a single mechanical part out of electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods using external shunts or knife switches are used to disable high voltage batteries, then the battery assembly can be disabled for safety during maintenance, but the device complexity, weight, and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functions (disconnection, insulation, and electrical contact) into a single shaft assembly that includes both conductive and non-conductive sections. This eliminates the need for separate external shunts or knife switches, directly reducing device complexity while maintaining safety functionality.
Solution Approach 2:
The shaft serves multiple functions simultaneously: it provides electrical connection when conductive, electrical insulation when non-conductive, and mechanical disconnection capability. This multi-functionality reduces the number of components needed while achieving the same safety objective.
2Reliability
If conventional methods using external shunts or knife switches are used to disable high voltage batteries, then the battery assembly can be disabled for safety during maintenance, but the manufacturing and installation cost increases
Solution Approach 1:
By merging multiple components into a single integrated shaft assembly, the patent reduces the number of parts that need to be manufactured and assembled, directly lowering manufacturing and installation costs while maintaining the safety disconnection function.
3Reliability
If conventional methods using external shunts or knife switches are used to disable high voltage batteries, then the battery assembly can be disabled for safety during maintenance, but the weight of the safety system increases
Solution Approach 1:
The patent consolidates multiple heavy components (external shunts, knife switches, mounting structures) into a single lightweight shaft assembly, directly reducing the weight of the safety system while maintaining its protective function.
Data Source
AI summary
In some embodiments, a battery safety disconnect system may have a first conductor and a second conductor operatively coupled to at least one battery cell. The battery safety disconnect system may also include a shaft having at least one non-conductive shaft section and at least one conductive shaft section operatively coupled together. The battery safety disconnect system may also include a housing that defines a channel to receive the shaft. The housing may also include a first pole and a second pole. A first conductive contact and a second conductive contact may be configured to facilitate an electrical connection when in contact with the at least one conductive shaft section. Pole fastenings may be configured to attach the poles to the conductors. An operator may be configured to facilitate engagement of the at least one conductive shaft section with the first conductive contact and the second conductive contact.