The Battery Module Electrical Connector Structure Design And Optimization Of BEV

The battery coxuld expand the battery during the charging and discharging process,and caused the failure of the entire outer frame of the module,and the over-current heating temperature of the electrical connector(busbar)could be rose,thereby melted the assembly and caused the internal short circuit of the battery module,and fire safety,explosion and other electrical performance safety issues happened.At the same time,the structural strength of the module will also cause failure when the vehicle was vibrated and suhjeted to impact loads.Once the electrical connector fails,it directly affects the overall vehicle performance and driver safety Therefore,from the persective of reliab ility and safety,this paper conducted structural design and researched on module electrical connectors.In this paper,the module of a BEV was selected from a new energy company.In the whole research process,LTD was selected as the prototype,and the design of the module and its electrical connectors was carried out with numerical simulation as the main part and experiment as the auxiliary part.First,the serial and parallel module scheme was analyzed in the whole battery package,and the high-voltage and low-voltage wiring forms were analyzed.Compared with its advantages and disadvantages,the scheme on the output pole side was selected to design the module.Then,three-dimensional simulation technology was used to simulate the expansion force and overflow temperature rise of the module at the level of single module.Then,acceleration impact simulation and vibration fatigue simulation of the whole vehicle level were carried out on the modules under various working conditions.According to the national standard GB/T31467.3,impact simulation and random vibration fatigue analysis were carried out on the module.On the premise of ensuring the stability and reliability of the module structure,structural design of the modutes and electrical connectors was completed.The main research work was as follows-①According to the customer’s needs,the basic structure design of the module was completed,and the connection between the battery cell and the aluminum(bus bar)and the advantages and disadvantages of the traditional single-layer short aluminum were analyzed.For the 2PSS(2 and 8 series)solution,two types of electric ity were selected.The joint design and related experiments verify the petformanee requirements of the structural parts.Finally,on the basis of satisfying the basic performance,the bridging material and structure selection were completed.②After the module structure and scheme were determined,the single-module-level expansion force simulation and over-current temperature rise ’simulation are carrried out,and the structural improvement was carried out based on the over-currant temperature rise result,and the structural improvement was improved.Limited,purely just changing the structure could not.made the over-current temp erature rose and fell.For this reason,the charging strategy was optimized according to the temperature graph,and the charging time of 1.6c was shortened,thereby lowering the temperature rise and satisfying the requirement could not melt the correspondin assembly.③According to the national standard GB/T31467.3,the module was subjected to impact simulation and random vibration fatigue simulation.The load was applied in the X,Y and Z directions of the model to identify tile structural strength of each structural component in the module design.Finally,the vibration impact was applied in order to verify that the entire module design met the corresponding national standard requirements.