Serviceable Mid-Pack Busbar for In-Vehicle Battery Isolation
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Solution Overview
Problem
Existing electric vehicle battery systems lack a convenient and safe method for in-vehicle service, maintenance, and repair of high-voltage battery packs, as technicians face challenges in disconnecting and servicing battery packs without reducing voltage levels or removing the packs from the vehicle.
Innovation Solution
The introduction of a serviceable busbar that splits the battery pack voltage in half, allowing technicians to disconnect high voltage from the rest of the vehicle while the battery pack remains inside, and enabling cross-compatible battery packs to be used by electrically coupling and decoupling battery cells through a jumper connector system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the battery pack remains installed in the vehicle for service, then service time and vehicle downtime are reduced, but technicians face safety risks from high voltage and cannot perform maintenance safely
Solution Approach 1:
The battery pack is segmented into two separate battery packs, each containing a portion of the total battery cells. This segmentation allows the system to operate with half-voltage when one pack is disconnected, enabling safe servicing while the other pack remains connected and provides power. The physical separation is achieved through individual housings and separate busbar connections for each pack.
Solution Approach 2:
A busbar with a removable jumper connector serves as an intermediary component between the two battery packs. This intermediary allows for easy electrical connection and disconnection of the packs, enabling technicians to isolate one pack for servicing while maintaining system operation through the other pack. The jumper connector provides a simple mechanical interface for achieving the half-voltage state.
2Object-affected harmful factors
If the battery pack is removed from the vehicle for service, then safe access to battery components is achieved, but service time increases and vehicle downtime increases
Solution Approach 1:
The battery system is divided into two independently serviceable battery packs that remain installed in the vehicle. Each pack can be individually accessed and serviced without removing the entire battery system from the vehicle. The segmentation allows technicians to work on one pack while the vehicle remains operational on the other pack.
Solution Approach 2:
The busbar with jumper connector is pre-configured with external access points and insulation features that enable safe servicing operations to be performed in advance or during vehicle operation. The design anticipates service needs by providing ready-access connection points and protective features before servicing begins.
3Ease of manufacture
If standard battery packs are used without mid-pack access, then manufacturing simplicity is maintained, but in-vehicle serviceability and maintenance capability are reduced
Solution Approach 1:
The battery pack design incorporates a mid-pack segmentation with a removable access panel that divides the pack into accessible sections. This segmentation allows standard manufacturing processes to be used while creating serviceable sections. The access panel can be removed to expose internal components like busbars and connectors for maintenance operations.
Solution Approach 2:
The busbar design incorporates multiple functions: it serves as an electrical conductor, a structural support element, and a service access feature. The jumper connector integrated into the busbar provides both electrical connection and a mechanical interface for service operations, combining multiple functions into a single component to maintain manufacturing simplicity while enabling serviceability.
Data Source
AI summary
The present solution is directed to systems and method for electrically disconnecting at least a portion of a battery pack using a busbar. The present solution can include a busbar to electrically couple with a battery pack between two groups of battery cells of the battery pack. The busbar can dispose at an opening of a housing of the battery pack. The busbar can be exposed by an access cover. The busbar can include a jumper connector electrically coupling one body of the busbar electrically coupled with a first group of battery cells of the battery pack with another body of the busbar electrically coupled with a second group of battery cells of the battery pack. The jumper connector can be accessible via the opening under the access cover to allow electrical decoupling of the first or second group of battery cells.