Contactor Box With Auto-Disengaging HV Connections for Battery Removal
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Solution Overview
Problem
Current electrical Energy Storage Systems (ESS) in vehicles face challenges with the safe and easy removal of high voltage connections, particularly due to the need for manual disconnection using levered connectors, which poses risks when voltage and current are present.
Innovation Solution
A contactor box with automatically disengaging incoming and outgoing high voltage connections that are easily accessible and securely fastened, allowing for safe and simple removal by pulling or lifting, reducing the risk of voltage and current hazards during installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If levered connectors are used for high voltage connections, then connection reliability is improved, but ease of operation deteriorates due to manual disconnection requirements and safety risks
Solution Approach 1:
The high voltage connection system is segmented into modular components: the contactor box with integrated connections and the battery terminals. This segmentation allows the contactor box to be removed as a complete unit with its high voltage connections already disengaged from the battery, eliminating the need for separate manual disconnection steps while maintaining connection reliability during operation.
Solution Approach 2:
The high voltage connections are designed to automatically disengage from the battery terminals before the contactor box is fully removed. This preliminary action of automatic disconnection occurs as part of the removal process itself, eliminating the need for separate manual disconnection steps and reducing safety risks associated with handling live connections.
2Reliability
If manual disconnection procedures are used, then safety control is improved, but loss of time increases due to complex disconnection steps
Solution Approach 1:
The high voltage connection system is designed to perform the disconnection action automatically when the contactor box is removed. The mechanical movement of removing the contactor box itself triggers the disengagement of high voltage connections from the battery terminals, eliminating the need for separate manual disconnection steps and reducing the time required while maintaining safety through automatic control.
3Reliability
If high voltage connections are made securely fastened, then connection reliability is improved, but ease of operation deteriorates due to difficulty in removal
Solution Approach 1:
The system is segmented into the contactor box assembly with integrated high voltage connections and the battery assembly. This segmentation allows the connections to be securely fastened to the contactor box while the entire contactor box unit can be easily installed or removed as a complete assembly, maintaining both connection stability and ease of operation at the modular level.
Solution Approach 2:
The high voltage connections are designed to automatically disengage from the battery terminals during the removal process, before the contactor box is fully separated. This preliminary automatic disengagement eliminates the need for manual unfastening of secure connections, maintaining connection reliability during operation while enabling easy removal of the contactor box.
Data Source
AI summary
The present disclosure relates to a contactor box for an electrical energy storage system of an at least partly electrical vehicle. The contactor box comprises a first ingoing high voltage connection adapted to be connected to a second ingoing high voltage connection of a battery. The contactor box comprises a first outgoing high voltage connection adapted to be connected to a second outgoing high voltage connection of the battery. The first ingoing and the first outgoing high voltage connections are adapted to be disengaged from the battery when the contactor box is removed from the vehicle, and adapted to be engaged with the battery when the contactor box is inserted into the vehicle.