Hybrid EV Battery Cover Interlock for Safe Maintenance Access
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Solution Overview
Problem
High voltage exposure points in hybrid electric vehicles are not adequately protected, posing a risk during maintenance and access operations.
Innovation Solution
A battery system with a service disconnect switch and a removably connected access panel that mechanically and electrically interlocks to prevent access to high voltage connections until intentionally disconnected, allowing safe access and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the access panel is permanently fixed to the battery cover, then protection against high voltage exposure is maximized, but access for maintenance and service operations becomes difficult
Solution Approach 1:
The access panel is segmented from the battery cover, allowing it to be removably connected rather than permanently fixed. This enables the panel to be detached for maintenance access while maintaining protection when attached, resolving the contradiction between safety and serviceability.
Solution Approach 2:
The access panel transitions from a static, permanently fixed state to a dynamic, removably connected state. This allows the system to adapt between two modes: protected (panel attached) and accessible (panel removed), resolving the contradiction between continuous protection and maintenance access.
2Ease of operation
If the access panel is made removable for easy access, then ease of operation is improved, but protection against accidental high voltage exposure deteriorates
Solution Approach 1:
The service disconnect switch acts as an intermediary between the access panel and the battery connection points. It provides a controlled intermediate state where the panel can be removed only after the disconnect switch is activated, preventing accidental exposure while maintaining ease of access.
Solution Approach 2:
The system requires preliminary action (activating the service disconnect switch) before the access panel can be safely removed. This preliminary safety step ensures that high voltage power is disconnected before access is granted, preventing accidental exposure while enabling controlled access.
3Reliability
If a service disconnect switch with interlock mechanism is added, then safety against accidental exposure is improved, but device complexity increases
Solution Approach 1:
The service disconnect switch combines multiple functions into a single integrated mechanism: electrical disconnection, mechanical retention of the access panel, and interlock control. This merging reduces overall system complexity compared to having separate components for each function while maintaining high safety standards.
Solution Approach 2:
The service disconnect switch serves multiple functions simultaneously: it disconnects electrical power, mechanically retains the access panel in the closed position, and provides interlock control. This multi-functionality reduces the need for additional separate components, thereby managing device complexity while enhancing safety.
Data Source
AI summary
A battery system includes a battery cover, a battery access panel removably connected to the battery cover, and a service disconnect switch. The service disconnect switch includes an electrical interlock switch. The service disconnect switch has a first position cooperating with the battery access panel to prevent removal of the access panel from the battery cover. In the first position, the service disconnect connects a traction battery to circuitry. The service disconnect also has a second position, the second position being displaced from the access panel and disconnecting the battery.