MSD-Mounted Contactor Retrofit for Certified Battery Packs
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Solution Overview
Problem
Existing battery packs with manual service disconnects (MSDs) require substantial modifications to integrate contactors, which is costly and time-consuming, and often necessitates complete recertification to ensure safety and functionality.
Innovation Solution
A system and method that allows for the efficient replacement of MSDs with contactors in battery packs by providing a set of batteries that include an MSD, removing the existing MSD, and installing a contactor at the MSD location, which can be electrically connected to the existing sockets and housed in a cavity with a similar form factor, enabling remote control and enhanced safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactors are integrated into battery packs with MSDs, then safety and remote control capability are improved, but device complexity and modification cost increase
Solution Approach 1:
The contactor housing is designed to perform multiple functions: it houses the contactor assembly, provides structural support, maintains seal integrity with the battery pack, and interfaces with existing MSD sockets. This multi-functionality reduces the need for additional components and minimizes device complexity while improving safety through remote control capability.
Solution Approach 2:
The contactor assembly is nested within the contactor housing, which itself is integrated into the battery pack structure at the MSD location. This nesting approach allows the contactor to be added without substantial modification to the overall pack structure, reducing device complexity while achieving the safety improvement of remote high voltage disconnection.
2Adaptability or versatility
If contactors are added to certified battery packs, then functionality is improved, but recertification requirements increase time and cost
Solution Approach 1:
The contactor housing and assembly are pre-designed and pre-tested as a complete unit that interfaces with existing MSD sockets. The design anticipates certification requirements by maintaining original seal integrity and structural characteristics, allowing the contactor to be added as a pre-validated module rather than requiring recertification of the entire battery pack.
Solution Approach 2:
The contactor integration is implemented locally at the MSD location without modifying other parts of the battery pack. The contactor housing maintains the same form factor and seal characteristics as the original MSD, ensuring that only the local area requires validation while the rest of the certified pack remains unchanged, thereby reducing recertification time and cost.
3Ease of operation
If MSDs are removed and contactors installed at the same location, then remote control capability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The contactor housing is designed as a copy of the original MSD housing in terms of external dimensions, mounting interfaces, and seal characteristics. This copying approach ensures that the contactor assembly fits into the existing MSD location without requiring precision modifications to the battery pack structure, thereby reducing manufacturing precision requirements while achieving remote control capability.
Solution Approach 2:
The contactor assembly is segmented into modular components (contactor element, housing, seals, mounting features) that can be independently manufactured and assembled. This segmentation allows each component to be manufactured to standard tolerances and then precisely fitted together, reducing the overall manufacturing precision requirements compared to creating a completely integrated assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for the integration of contactors into battery packs without significant redesign, improving safety by enabling remote control of high voltage connections, reducing the risk of short circuits, and avoiding the need for extensive recertification, while maintaining the existing cable connections and seal integrity.
Implementation Method 1
Relays are known to have coils for generating a magnetic force that mechanically operates an electric contact. Contactors often do the same, but relays are for low and medium power whereas contactors operate for high power devices.
Data Source
AI summary
A system may be configured to replace a manual service disconnect (MSD). Some embodiments may: provide a set of batteries that include an MSD; remove the MSD; and install a contactor at the MSD. The replacement may be performed via substantially similar housing previously used by the MSD.