Foldable HV Busbar Access for EV Battery Service
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Solution Overview
Problem
Servicing High Voltage Distribution Systems (HVDS) in electric vehicles is costly, labor-intensive, and requires complex procedures, often necessitating specialized facilities and resulting in reduced service revenue due to high downtime.
Innovation Solution
The implementation of a detachable and foldable busbar architecture with floating fasteners allows for servicing without removing components, enabling ease of access to power electronics systems by reconfiguring the busbar sections and support trays, thereby reducing downtime and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional fixed busbar architecture is used, then structural stability is maintained, but servicing complexity and downtime increase
Solution Approach 1:
The busbar support structure is divided into multiple sections with different degrees of freedom. The first support section is fixed to the battery housing, while the second support section is movable relative to the first section, allowing selective access to different components without removing the entire busbar assembly.
Solution Approach 2:
The busbar support transitions from a static fixed structure to a dynamic structure with movable sections. The second support section can be moved between a first position (for normal operation) and a second position (for servicing), enabling flexible access to power electronics components while maintaining structural integrity during operation.
2Ease of operation
If complete busbar removal is performed for servicing, then full access to power electronics is achieved, but service time and labor intensity increase
Solution Approach 1:
The support structure is segmented into fixed and movable sections, allowing the second support section to be independently moved to provide access to specific components while the first support section and busbar remain in place, eliminating the need for complete removal.
Solution Approach 2:
The movable second support section can be extracted or moved away from its normal position to provide access to the power electronics components, while the rest of the busbar assembly remains installed and functional.
3Reliability
If specialized servicing facilities are used, then proper handling of high voltage components is ensured, but service cost increases
Solution Approach 1:
The battery system incorporates self-service features through the movable support section that allows technicians to access and service high voltage components directly at the installation location without requiring specialized external facilities, reducing service costs while maintaining safety through designed access mechanisms.
Data Source
AI summary
A battery system for an electric vehicle includes a fixed cover, and a removable cover arranged over battery modules and a high voltage distribution system. The battery system includes a busbar arranged at least partially over a region of the battery modules and under the removable cover. The busbar includes a fixed section and a movable section, or a hinge, such that the busbar can be repositioned out of the way. The support tray includes a link between the fixed and movable sections. Floating fasteners, allowing at least one of radial float and axial float are used to secure the link to the support tray, thereby avoiding safety hazards and reducing the potential for short circuits in high voltage distribution systems or conductors thereof. The floating fasteners include a head, a neck, an engagement section, and a washer, which prevent removal from a component once installed.