Battery Switching Element for Safe High-Voltage Assembly
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Solution Overview
Problem
The manufacture and handling of high-voltage batteries for motor vehicles pose significant safety risks due to the potential for electrical shock and energy release, requiring costly and time-consuming safety measures, as well as risks to workers, customers, and first responders, since voltages over 60 volts cannot be detected by human senses and are life-threatening.
Innovation Solution
A method where a switching element is used to interrupt the electrical connection between the galvanic element and the connection terminals of battery cells during assembly, allowing the battery to be safely assembled and deactivated, with a semiconductor control unit ensuring the connection is only made when necessary to provide the rated voltage, thereby minimizing the danger of high voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells are connected in series to form high-voltage batteries (>60 volts), then the rated voltage of the battery is increased to provide sufficient drive energy for motor vehicles, but the safety risk to workers during manufacture increases due to life-threatening electrical voltages that cannot be detected by human senses
Solution Approach 1:
The switching element is brought into a switching state that interrupts the electrically conducting connection between the arrester and the electrical connection terminal before the battery cells are connected in series. This preliminary action ensures that no voltage is present on the connection terminals during assembly, eliminating the electrical shock risk to workers while allowing high-voltage operation after assembly when the switching element is activated
Solution Approach 2:
The switching element acts as an intermediary between the arrester and the electrical connection terminal, controlling the electrical connection. By introducing this intermediate component, the system can maintain high voltage for power delivery while preventing direct exposure of workers to hazardous voltages during manufacture and handling
2Object-affected harmful factors
If appropriate protection measures are implemented for high-voltage battery manufacture, then the safety of workers is improved, but the manufacturing cost increases due to expensive protective equipment and extensive training requirements
Solution Approach 1:
The switching element is configured to interrupt the electrical connection before battery cells are connected in series during assembly. This preliminary safety measure eliminates the need for expensive protective equipment and extensive training, as workers handle only low-voltage components during manufacture while the high-voltage function is activated only after assembly is complete
3Ease of operation
If battery cells are precharged during manufacture, then the battery cells are ready for operation, but the electrical danger to persons increases since life-threatening high voltages are present on the connection terminals during assembly
Solution Approach 1:
The switching element is brought into a switching state that interrupts the electrical connection before battery cells are connected in series, allowing precharged cells to be safely assembled without exposing workers to high voltage. The high-voltage operation is activated only after assembly is complete, combining battery readiness with worker safety
Solution Approach 2:
The switching element serves as an intermediary that isolates the precharged battery cells from the connection terminals during assembly. This allows the cells to maintain their charged state for operational readiness while preventing hazardous voltage exposure to workers during the manufacturing process
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
This approach enables the safe assembly and operation of high-voltage batteries by ensuring no voltage is present on the terminals until the switching element is closed, reducing the risk of electrical hazards during manufacturing and in emergency situations, and allows for intelligent control of the battery cells based on various parameters.
Implementation Method 1
an electrically conducting connection between an arrester (16) of the galvanic element and at least one of the electrical connection terminals (20) of the battery cell (10) is produced through the switching element (24)
Data Source
AI summary
A battery for a motor vehicle, in which electrical connections of a plurality of battery cells, are connected by at least one electrically conducting connection element. The battery cells have a galvanic element. The battery cells are connected so that a rated voltage is provided by the battery which is greater than the rated voltage of one of the battery cells. After connecting the electrical connection terminals of at least two battery cells, a switching element of one of the battery cells, arranged between an arrester of the galvanic element and one of the electrical connection terminals, is brought into a switching state in which an electrically conducting connection between an arrester of the galvanic element and at least one of the electrical connection terminals of the battery cell is produced.