![]() ![]() ![]() Without the precharge resistor, today’s low resistance batteries can supply many thousands of amps if suddenly connected to a low resistance load. The precharge circuit consists of an additional contactor and a resistor that controls the flow of current into the high voltage vehicle bus as capacitance on the vehicle bus is charged up to the battery pack voltage. That control is provided by the precharge circuit. Thus, the transition must be a controlled process. Pre-charge circuitĪs a battery pack closes the contactors and transitions from a disconnected state to a connected state, there is a possibility for momentary but very large currents. Their functionality and operating limits such as interrupt current rating and voltage rating must all be thoroughly understood. The secondary safety function qualifies the contactors as a critical safety device in a modern high voltage battery pack. For example, the contactors can be opened by the battery management system if a charger failure allows the charger to begin overcharging the battery pack. However, contactors are also a safety item that can be opened to disconnect the battery pack if some part of the vehicle malfunctions and is forcing the battery pack outside its design envelope. ContactorsĬontactors are electrically actuated switches that are primarily used to disconnect the battery pack from the vehicle’s high voltage system when the vehicle is not in use. High/hazardous voltage integrity/interlock loop (HVIL) circuit. This is accomplished through the use of the following components whose functionality will be discussed below: The battery pack high voltage system is designed to control power flow to and from the cells and to maintain the power level within the design envelope. In addition, advanced manufacturing methods, for example, 3D-printing, the dry electrode method, and cell-to-pack technology, which have the potential to push the development boundaries further are introduced within. Advancements made in materials domain with an aim to develop the next-generation Li-ion batteries are concisely described within this chapter. Therefore research is underway to develop novel electrode and electrolyte materials and battery manufacturing methods. Choices related to both the materials used in Li-ion batteries and methods used to manufacture the batteries influence their performance. ![]() This chapter focuses on the two design aspects that are central to engineering reliable battery packs-material selection and manufacturing method.īatteries with high energy density, high power density, and long cycle life are needed to support the faster introduction and smooth integration of electric vehicles within our society. Kari Tammi, in Heavy-Duty Electric Vehicles, 2021 4.4 Summaryīattery packs form the core of electric vehicle technology. Materials and Manufacturing Methods for Advanced Li-ion Batteries ![]()
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