Within a battery pack there will be a large number of connectors. These will be low voltage (LV) power / signal types and high voltage (HV) connectors. These pages will concentrate on the HV from the bolted joint through to the main power connections on the pack.
Bolted Joints
Bolted joints are common inside HV battery packs. However, there are a few things to consider:
- joint resistance
- material compatibility
- thermal cycling
- corrosion
- vibration
- torque resistance
- tooling access
Bolted joints are commonly used to join solid busbars to modules, contactors or to other busbars.
Examples of Busbar Bolted Joint Design – there are so many things to think about in any busbar bolted joint design. Hence it is useful to look at examples and experience.
Charging Connectors
There are many Types of EV Charging Connectors in the world. It’s bit confusing sometimes for a Beginner to understand. The outlet of the charging station whether at Home or work or in Public has to match the outlet of your car. The Plug on the charging cable at either end specifically makes the difference.
HVIL
High Voltage Interlock Loop – in high-voltage systems, potential leakage currents or connection failures pose risks to both the vehicle’s electronics and users. HVIL instantly detects such conditions and initiates a power cutoff. This ensures that during an accident, the vehicle’s high-voltage system is rapidly deactivated, protecting both occupants and first responders. It also safeguards technicians during maintenance and repair operations. Standards such as IEC 61851 and ISO 26262 mandate the use of HVIL.
Legislation, Rules and Regulations
- IEC 62196-1 covers the general dimensional and safety requirements common to all conductive-charging plugs, socket-outlets, vehicle connectors and inlets.
- IEC 62196-2 defines the dimensional interchangeability requirements for AC pin-and-sleeve connectors, including the Type 1 and Type 2 connectors used on this page.
- IEC 62196-3 defines the dimensional interchangeability requirements for DC and combined AC/DC connectors, including the CCS connector family.
- SAE J1772 is the North American standard defining the physical, electrical and communication requirements for the J1772 AC charging connector.
- SAE J3400 standardises the North American Charging Standard (NACS) connector, originally Tesla’s proprietary design, for both AC and DC charging.
Low Voltage Connections
Low voltage power and signal connections need covering in their own right.