Investigation of the electro-mechanical behavior of automotive high voltage busbars under combined electrical load with varying indenter geometry and environmental conditions

Werling, Tobias; Geuting, Peter; Höschele, Patrick; Ellersdorfer, Christian; Sinz, Wolfgang

doi:10.1016/j.est.2020.101861

Cited by 10 publications

(17 citation statements)

References 25 publications

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“…In comparison, the PA12 Cu-OFE R240 busbar showed a significant increase in critical values compared to quasi-static tests until electrical failure in the form of a short circuit occurred. The phenomenological behavior of PA12 was similar to the quasi-static observed one [ 12 ].…”

Section: Discussionsupporting

confidence: 71%

“…In the following, the results of the conducted dynamic characterization tests (solid blue line) with indenter geometries V1, V4 and V5 are compared against quasi-static characterization tests (solid black line) obtained from Werling et al [ 12 ]. The comparison is made in the form of force–displacement diagrams using the calculated mean value curves.…”

Section: Results and Discussionmentioning

confidence: 99%

“…This was necessary in order to avoid an electric arc from the busbar to the SHPB bars and to the attached strain gauges. Within previous quasi-static characterization tests (see [ 12 ]), a total of six different impactor types (V1 to V6) were used. In this study, the three most relevant types (V1, V4 and V5), see Figure 3 b–d, respectively, as identified in the previous study, were used.…”

Section: Materials and Methodsmentioning

confidence: 99%

“…The HVBs’ position within the battery pack enlarges the risk of failure due to a vehicle crash. Commonly placed on the outside or in between the cell modules, intruding objects or other battery components can damage the HVB and its insulation [ 12 ].…”

Section: Introductionmentioning

confidence: 99%

“…Requirements for electrical and thermal performance are derived from high-voltage cable regulations, e.g., [ 13 , 14 ]. Werling et al [ 12 ] investigated the electro-mechanical behavior of HVBs using a quasi-static compression test combined with insulation resistance measurement. The test setup allowed interchangeable indenter geometries and electric potentials of 1000 V. They showed that, depending on the intruding object, the HVB can undergo large plastic deformation.…”

Section: Introductionmentioning

confidence: 99%

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On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar

et al. 2021

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High-voltage busbars are important electrical components in today’s electric vehicle battery systems. Mechanical deformations in the event of a vehicle crash could lead to electrical busbar failure and hazardous situations that pose a threat to people and surroundings. In order to ensure a safe application of busbars, this study investigated their mechanical behavior under high strain rate loading using a split Hopkinson pressure bar. Two different types of high-voltage busbars, consisting of a polyamide 12 and a glass-fiber-reinforced (30%) polyamide 6 insulation layer, were tested. Additionally, the test setup included a 1000 V electrical short circuit measurement to link the electrical with the mechanical failure. It was found that the polyamide 12 insulated busbars’ safety regarding insulation failure increases at high loading speed compared to quasi-static measurements. On the contrary, the fiber-reinforced polyamide 6 insulated busbar revealed highly brittle material behavior leading to reduced bearable loads and intrusions. Finally, the split Hopkinson pressure bar tests were simulated. Existing material models for the thermoplastics were complemented with an optimized generalized incremental stress state-dependent model (GISSMO) with strain rate dependency. A good agreement with the experimental behavior was achieved, although the absence of viscoelasticity in the underlying material models was notable.

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Section: Discussionsupporting

confidence: 71%

Section: Results and Discussionmentioning

confidence: 99%

Section: Materials and Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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