Battery Rack MSD and Fusing Bus Bar for Short-Circuit Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High voltage energy storage systems (ESS) face safety risks during transportation and installation due to the risk of short-circuits and explosions, and conventional solutions like separate fuses increase costs and reduce energy efficiency.
Innovation Solution
A high voltage battery rack with a manual service device (MSD) module that determines and breaks high voltage at external terminals, a fusing bus bar acting as both a bus bar and a fuse, and a double safety device that switches off contactors when high voltage is exposed, preventing secondary short-circuits and allowing visual confirmation of the ruptured state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fuses are used in each battery module to prevent short-circuit accidents, then safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The bus bar is designed to function as both a current conductor and a fuse element. When overcurrent occurs, the bus bar itself ruptures to interrupt the circuit, eliminating the need for separate fuse components while maintaining safety protection
Solution Approach 2:
The bus bar performs multiple functions: it conducts current during normal operation and acts as a protective fuse during overcurrent conditions. This multi-functionality reduces the total number of components needed in the battery module
2Reliability
If separate fuses are installed in each battery module, then safety is improved, but energy efficiency decreases due to space occupation
Solution Approach 1:
The protective fuse function is merged into the bus bar structure itself. The bus bar's conductive material and geometry are designed to serve as the fuse element, eliminating dedicated fuse space and improving energy efficiency by reducing inactive component volume
3Reliability
If the MSD module is used to determine and break high voltage at external terminals, then operator safety is improved, but device complexity increases
Solution Approach 1:
The MSD module allows operators to manually open the circuit and disconnect high voltage terminals before performing maintenance or transportation operations. This preliminary action prevents accidental exposure to high voltage and eliminates the need for more complex automated detection and interruption systems
Solution Approach 2:
The MSD module serves as a simple intermediary device that physically disconnects the high voltage circuit. This mechanical switching mechanism is simpler than electronic detection and control systems while providing adequate safety for operator protection
4Reliability
If contactors are equipped with double safety switching capability, then safety is improved by preventing secondary short-circuits, but device complexity increases
Solution Approach 1:
The contactor is designed with inherent safety features that prevent secondary short-circuits even if the first protective layer fails. This might include isolated contact chambers, arc suppression mechanisms, or mechanical interlocks that ensure safe operation without requiring additional complex control systems
Solution Approach 2:
Specific regions of the contactor are designed with enhanced safety characteristics, such as localized insulation barriers or magnetic field containment zones, that provide targeted protection without requiring the entire device to be overly complex
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances operator safety by manually and visually confirming high voltage conditions, eliminates the need for separate fuses, and prevents secondary short-circuits, thereby improving safety and efficiency during transportation and installation.
Implementation Method 1
an MSD module configured to determine whether a voltage is applied to the external terminals during operation
Implementation Method 2
a fusing bus bar capable of serving as both a bus bar and a fuse in each battery module
Data Source
AI summary
The present invention provides a high voltage battery rack, including: a plurality of battery modules electrically connected with each other; and a rack controller configured to control the plurality of battery modules, wherein each of the plurality of battery modules comprises: external terminals; and an MSD module configured to determine whether a voltage is applied to the external terminals during operation.