Foldable HV Busbar Layout for Easier EV Battery Servicing
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Solution Overview
Problem
Servicing high voltage distribution systems in electric vehicles is costly, complex, and labor-intensive, often requiring specialized facilities and leading to reduced service revenue due to high downtime.
Innovation Solution
A detachable and foldable busbar architecture with floating fasteners allows for easy access to power electronics without removing components, featuring a fixed and flexible busbar section connected by hinges and insulative trays, enabling reconfiguration for service access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional fixed busbar architecture is used, then structural stability is maintained, but servicing complexity and downtime increase
Solution Approach 1:
The busbar is divided into fixed and removable sections, allowing the removable section to be detached for servicing while the fixed section remains in place. This segmentation enables selective access to power electronics without requiring complete disassembly of the entire busbar structure, thereby reducing servicing complexity and downtime.
Solution Approach 2:
The busbar incorporates a removable section that can be dynamically detached and reattached, transforming the static fixed structure into a dynamic configurable system. This allows the busbar architecture to adapt between operational mode (fixed) and servicing mode (removable section detached), improving ease of operation without compromising structural stability during normal operation.
2Ease of operation
If complete component removal is required for servicing, then access to power electronics is achieved, but downtime and labor intensity increase
Solution Approach 1:
The busbar is segmented into fixed and removable portions, enabling technicians to remove only the necessary section for accessing power electronics rather than completely disassembling the entire busbar assembly. This partial removal approach significantly reduces service downtime while maintaining adequate access to components.
Solution Approach 2:
The removable section of the busbar is extracted from the fixed structure, allowing independent removal of only the portion needed for servicing. This extraction principle enables selective access to power electronics without disturbing the entire busbar system, thereby minimizing downtime and labor intensity.
3Ease of manufacture
If floating fasteners are used, then assembly tolerance variability is accommodated, but fastener design complexity increases
Solution Approach 1:
The fastener design incorporates floating capability that allows positional parameter variations within tolerance ranges. The fastener can float or shift within defined limits to accommodate variability in assembly dimensions, enabling easier manufacturing and assembly without requiring precise tolerance control, thus improving ease of manufacture.
4Ease of repair
If removable busbar sections are implemented, then servicing ease is improved, but structural integrity during operation may be compromised
Solution Approach 1:
The busbar is divided into fixed and removable sections with distinct functional roles. The fixed section provides continuous structural support during operation, while the removable section is designed for periodic maintenance. This segmentation allows the fixed portion to maintain structural integrity while the removable portion enables ease of repair.
Solution Approach 2:
The removable section is pre-configured with attachment and detachment mechanisms that ensure proper reinstallation after servicing. This preliminary preparation of the removable section ensures that when reattached, the structural integrity and reliability of the complete busbar assembly are restored to operational specifications.
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.