Lithium-Ion Battery Connector Arcing Prevention

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Solution Overview

Problem

Existing power systems, such as UPSs, face challenges in safely disconnecting lithium-ion batteries without causing electrical arcing, which can damage connectors, especially when high current is involved, leading to the need for larger and more expensive connectors.

Innovation Solution

A power system with an external-battery-power terminal and an emergency power off (EPO) switch, triggered by a mechanical latch, which decouples the battery from the power system, ensuring safe disconnection by terminating the EPO signal and shutting down power before physical removal, preventing arcing and connector damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If connectors are designed to resist arcing when connecting and disconnecting high current batteries, then connector reliability is improved, but connector size and cost increase

Engineering Contradiction:

Improveconnector reliabilityVSAvoidconnector size

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The system performs preliminary action by detecting connector disconnection intent and preemptively reducing battery current to zero before the connector is physically disconnected. This prevents arcing at the moment of disconnection without requiring oversized connectors, thereby maintaining reliability while avoiding increased connector size and cost.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If connectors are designed to resist arcing during high current disconnection, then connector durability is improved, but connector cost increases

Engineering Contradiction:

Improveconnector durabilityVSAvoidconnector cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The control system performs preliminary action by detecting connector disconnection intent and preemptively reducing battery current to zero before physical disconnection occurs. This eliminates arcing damage without requiring expensive arc-resistant connector designs, thereby maintaining durability while reducing manufacturing cost.

Inventive Principle:

Principle #10Preliminary action

3Speed

If current is not reduced before connector disconnection, then system response time is improved, but electrical arcing occurs causing connector damage

Engineering Contradiction:

Improvesystem response timeVSAvoidelectrical arcing

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary action by detecting connector disconnection intent through loss of communication or control signals, then preemptively reducing battery current to zero before the connector is physically disconnected. This sequence prevents electrical arcing while maintaining fast system response through automated detection and actuation.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20240421409A1System and method to connect and disconnect one or more lithium-ion battery

Publication Date: 2024.12.19 SCHNEIDER ELECTRIC IT CORP

AI summary

A power system includes an external-battery-power terminal configured to receive an external-battery-power connector, an external battery emergency power off (EPO) terminal, and an EPO switch coupled to the EPO terminal. The EPO switch is configured to be triggered by decoupling a mechanical latch associated with the external-battery-power connector. An EPO signal is manipulated when the EPO switch is triggered to decouple a battery from the external-battery-power terminal.