Battery Safety Interlock for Electric Vehicle Terminals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery safety systems with single action arrangements may allow access to high voltage when the guard is partially removed, posing a risk of electrical shock from battery terminals.
Innovation Solution
A double action safety interlock system that requires the terminal guard to be properly positioned before allowing electrical connection to the battery terminal, ensuring battery voltage is only coupled when the guard is in a protected position, thereby preventing inadvertent contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single action arrangement is used to disconnect battery voltage when the guard is removed, then the device complexity is reduced, but the safety reliability deteriorates because small objects can access battery voltage when the guard is partially removed
Solution Approach 1:
The safety system is divided into two independent interlock mechanisms: a first interlock that prevents guard removal when voltage is present, and a second interlock that prevents voltage application when the guard is not properly positioned. This segmentation ensures that both protective functions must be satisfied simultaneously, preventing electrical shock even during partial guard removal.
Solution Approach 2:
The system performs preliminary safety checks before allowing voltage application. The first interlock checks whether the guard is properly positioned before allowing removal, and the second interlock checks whether the guard is fully positioned before allowing voltage connection. These preliminary actions ensure safety conditions are met before critical operations occur.
2Ease of operation
If the guard can be partially removed to allow cable access, then the ease of operation is improved, but the safety reliability worsens because the electrical connection between battery terminal and voltage remains present
Solution Approach 1:
The system dynamically controls both the mechanical guard position and electrical voltage state through two interlocks. The first interlock dynamically prevents guard removal when voltage is present, while the second interlock dynamically prevents voltage application when the guard is not fully positioned. This dynamic control allows safe operation sequences while preventing dangerous states.
Solution Approach 2:
The two interlock mechanisms act as intermediary safety layers between the guard position and voltage application. The first interlock mediates between voltage presence and guard removal, while the second interlock mediates between guard position and voltage connection. These intermediaries ensure that unsafe transitions are blocked while allowing safe operations.
Data Source
AI summary
A battery safety system that includes a battery terminal configured for making an electrical connection to the system, an electrical disconnect operable to a disconnected state whereby a battery voltage is electrically isolated from the battery terminal, and a connected state, whereby the battery voltage is electrically coupled to the battery terminal. The battery safety system also includes and a terminal guard movable to an exposed position effective to allow making the electrical connection to the battery terminal, and a protected position effective to prevent electrical contact with the battery terminal other than via the electrical connection. The system is configured to prevent the electrical disconnect from being operated to the connected state if the terminal guard is not at the protected position. The system provides a double action safety interlock that makes the action of connecting and disconnecting battery voltage to and from battery terminals or battery cables separate from the action of covering and uncovering the battery terminals, and so reduces the risk of electrical shock when the battery is being manufactured, installed, serviced, or otherwise handled.