high voltage battery and power distribution technology · pdf filekevin vickers – tata...

High Voltage Battery and Power Distribution Technology
Presentations by:
Kevin Vickers Tata Motors Ltd
Richard Senter Zytek
Michael Nicholas - JLR
Presentation on the Implications of Distributed Battery Modules - Kevin
Passive & Active HV Power Distribution Units - Richard
Design For Assembly Design considerations and actions - Michael
Workstream 4 Leader Kevin Vickers, Tata Ltd MAY 2011
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High Voltage Battery and Power Distribution Technology
Presentation on the Implications of Distributed Battery Modules
The purpose of any HV electrical system is to convey the HV energy between source and sink, maintaining isolation
from the vehicle and being able to shut down the system safely in the event of any defined fault. This Presentation
highlights some more familiar aspects of consideration in achieving these requirements
Passive & Active HV Power Distribution Units
From simple Non-Complex Junction Boxes to complex, Fault monitored Power Distribution units, this presentation deals
with both and highlights the significant differences to be considered for any Vehicle HV Electrical Architecture Design.
Design for Assembly Considerations for the design and vehicle layout with respect to Component packaging and locations, best working practices for
Operative Health and safety and suggested optimal cable and connector for HV systems forethoughts regarding vehicle Platform type.
Workstream 4 Leader Kevin Vickers, Tata Ltd MAY 2011

WS4 - High Voltage
Electrical Distribution Systems
Work stream 4 partners:
Kevin Vickers - TMETC
Richard Senter - Zytek
Mike Nicholas - JLR
Gunny Dhadyalla - WMG
Robert Ball - Ricardo

WS4 - How it all fits together
Vehicle
Benchmarking
4.2
Cable/Connector
Benchmarking
4.2
EMI/Thermal
Modelling
4.5
Standards
Review
4.1
Vehicle Build
Process
4.6
Optimisation
4.4
Vehicle End-of-life
Process
4.6
Need for new
components
4.3

Task 4.2- Benchmarking
High Voltage Electrical Distribution System (HV EDS)
> HV architectures
> HV practical installation issues
Components
> Cables
> Connectors
> Contactors

Task 4.2- HV Architectures
How do current EV/hybrid vehicles install/protect their HV components?
How should a distributed battery pack be connected/protected?
One big battery
E.g. Nissan, Renault
Distributed battery
E.g. Ford, Tata

HV Architectures- Benchmarking
Typical current vehicle Teardown Report:

HV Architectures- Distributed Battery
What hazards (shock, fire, smoke, loss of power, etc..)
Which existing standards (tend to treat the battery as a single component)
What tasks does the HV EDS need to do? (what vehicle use cases exist?)
How best to deal with a) series or b) parallel battery configurations?

Hazards:
> electric shock of individuals (from DC supplies, vehicle-generated AC supplies
and externally connected AC mains supplies)
> fire/smoke/noxious gasses caused by overheating within the battery or within
the vehicle wiring
> single failures that could otherwise lie hidden and mean that a further failure
could lead to electric shock or overheating
> loss of drive power in a critical road situation due to internal shutdown
> failure to comply with existing or future standards or legislation in this area

Standards relevant to distributed battery question:
> ECE/TRANS/WP.29/2010/52 (ECE R100 amended)
> SAE J2289
> SAE J2344
> ISO 6469-1-2009
> Cell manufacturers own guidance documents

Combinations of
Contactors
Service Disconnect switches
Fuse
To meet existing safety standards (and envisaged
vehicle Use Cases) without adding excessive
unreliability.
Case 1 individual module being
built/stored/tested/installed/dismantled, off-vehicle
Case 2 module being operated as part of a battery, on-vehicle
(vehicle being built/driven/serviced/dismantled)
Module 1
Module 3
Inverter
DC/
DC
Fgure 4- Series Battery
configuration
Module 2
Inverter
DC/DC
Contactor at positive end of series
chain
Contactor at negative end of
series chain
Imanual Isolator switches at
negative terminal of each
module
Imanual Isolator switches at
poles of each module
Central fuse

Alternative solution for parallel-
connected modules
Module 1
Module 3
Inverter
DC/
DC
Figure 5- Parallel Battery
configuration
Module 2
Inverter
DC/DC
Contactor at positive end of each
module
Manual Isolator switch at
negative end of each module
HV
JB
330V
HV Junction Box
Contactor at negative end of
paralleled modules
Main & precharge contactors at
positive end of paralleled modules
Central fuse
330V
330V

HV Architectures - Distributed Battery
Identified needs:
Connectors suitable for HV multiple battery applications
Contactors that will be reliable enough for a multiple-battery application
Service Disconnect switches that can be operated together from a single
operator action (particularly for the first responder)
Cost-effective HV Junction Box designs that integrates pre-charge, charger,
auxiliary load and possibly discharge contactors: Task 4.3

Task 4.3- HV PDU
Task 4.3 Development Activities
Simple Passive HV PDU (Power Distribution Unit) High Voltage Junction Box

Task 4.3- HV PDU
The diagram is a representation of a very simple passive PDU. This may also be referred to as a HV Junction Box. A typical use of this type of PDU might be to act as a coupling on the HV battery cable.

Task 4.3- HV PDU
The diagram is of a representation a more complex passive PDU. This may also be referred to as a HV Junction Box. A typical use of such a PDU would be to allow low power HV loads to take off HV power with the fuse providing protection for the low power HV cable

Task 4.3- HV PDU
Potential Uses A break in the HV harness to ease vehicle production.
Reduce total harness weight for handling purposes. Allows for remote location of battery in luxury vehicles
Allow for transitions through body panels inside to outside, for example
Allows for a more remote location of the HV battery, easing package constraints.
Allow the coupling of mixed cable materials within the system Aluminium to Copper, for example Cable to bus bar
Allow for low power HV equipment to draw HV power from the system.

Task 4.3- HV PDU
Advantages Simple design requirements Low Cost Low Mass Simplified validation requirements
EMC requirements are significantly simplified for a passive coupling Safety Testing is simplified,
CE/UL marking not required e-marking not required
Simplified FMEA analysis

Task 4

high voltage battery and power distribution technology · pdf filekevin vickers – tata...

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