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The contactor coil power supply is usually passed through a HVIL or high-voltage interlock loop, which loops through all the high voltage components in the system alongside the high voltage cables (usually incorporated into each connector), such that the contactor cannot receive power to close unless all the high voltage connections are securely plugged in to the battery.Ī pre-charge contactor closes before the main contactors, to allow a small current to flow into the system through a large resistor. They also often incorporate an auxiliary contact to detect internal welding which may occur if the contactor is intentionally or unintentionally opened while a large current is passing through it. Images from PanasonicĬontactors incorporate features such as a sacrificial contacts to prevent increasing resistance due to contact pitting.
TESLA CAR BATTERY OVERVIEW SERIES
Special high-current, sealed relays known as contactors connect the internal fuses to the battery, itself.Ī series of Panasonic EV relays/DC contactors (left) and a breakdown of a contactor's structure. The battery represents multiple challenges for safety when it comes to design, as well as regarding the high voltages permanently present within them.įuses are present inside the battery pack before the output connector, often on both the positive and negative side. Safety in EV Batteries: Contactors (and Pyro Fuses)
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Electric vehicles: 30 to 100 kWh or more.They also prevent the ability to use DC fast-charging stations of a lower voltage without incorporating some type of DC-DC boost converter in the on-board charger.Ĭommon battery capacity ranges, on the other hand, are as follows: The drawbacks of higher voltages include the necessity for higher-voltage-rated components in the entire system. The reason for this is higher voltages allow more power to be transferred with less loss over the same diameter (and mass) of copper cable.Īn example EV battery system with individual cells in series. For example, a 400V nominal pack will often have around 96 series blocks (as in the Tesla Model 3).Ĭommon nominal pack voltages in current vehicles range from 100V-200V for hybrid/plug-in hybrid vehicles and 400V to 800V and higher for electric-only vehicles. A common pack is composed of blocks of 18-30 parallel cells in series to achieve a desired voltage. EV Battery Specs: Voltages and CapacitiesĪn electric vehicle battery is often composed of many hundreds of small, individual cells arranged in a series/parallel configuration to achieve the desired voltage and capacity in the final pack. Here's an overview of some of the specifications, safety considerations, and management systems that go into EV battery design. As the main contributor to weight in an EV, designers must also consider the battery's placement within a vehicle as they can affect power efficiency and vehicle handling characteristics (which is typically why you'll often see batteries placed under the floor pan of the vehicle).
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This includes physical constraints such as efficient packaging within the vehicle’s body to maximize capacity.
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The battery must be designed to satisfy the requirements of the motor(s) and charging system that a vehicle utilizes. The fundamental piece of any electric vehicle (EV) is its battery. Here's a look at the heart of every EV: the battery. Electric vehicle design is a complex concept.