动力电池系统电连接技术要点.ppt

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,*,动力,电池,系统电连接,技术,目录,动力电池系统电连接技术概览,1,影响,Busbar,/,高压导线的载流因子,2,Busbar,/,高压导线计算选型方法,3,Busbar,/,高压导线测试标准和方法,4,铜铝连接技术,5,Pack,电气安全,设计,6,动力电池系统电连接技术概览,1,影响,Busbar,/,高压导线的载流因子,2,Busbar,/,高压导线计算选型方法,3,Busbar,/,高压导线测试标准和方法,4,铜铝连接技术,5,Pack,电气安全,设计,6,常见,EV,车的电气架构,RESS,Battery,),Inverter,E-Motor,Onboard,Charger,Climate,Compressor,PTC Heater,DC/DC,Convertor,MSD,BDU,LV Battery,动力电池系统电连接技术概览,来自,GB/T 18384.3,高低压分水岭,Item,Requirement,Voltage/Current,850VDC/Cat 1(up to 40A)Cat 2(up to 250A),Temperature requirements,-40C up to+140C,Electrical insulating strength,2700VDC(2xUmax+1000V),Insulating strength,Insulating resistance 200MOhm,testing voltage 1075 VDC,Shielding,Single-or Family-Shield,general 360 all arround,Shielding contact resistance,Max.10mOhm after lifetime,Insertion/retention force,Max.100N(or mechanical assistance),Mating cycle,Min.50 Mating cycles,Interlock-System(HVIL),required,OEM,对高压部分的主要要求参数,高压部分用橙色,色,卡,RAL 2003,+,-,-,+,+,-,+,-,+,-,+,-,+,-,-,+,-,+,-,+,-,+,-,+,+,-,-,+,+,-,+,-,+,-,+,-,+,-,-,+,-,+,-,+,-,+,-,+,+,-,-,+,+,-,+,-,+,-,+,-,+,-,-,+,-,+,-,+,-,+,-,+,+,-,-,+,+,-,+,-,+,-,+,-,+,-,-,+,-,+,-,+,-,+,-,+,MSD,PDU,模组,1,模组,2,模组,3,模组,4,Module,之间,Cell,之间,Pack,与,外部之间,方型,圆柱型,软包,高压线束,铜排,铜导线,铝导线,扁平铜,/,铝排线,动力电池系统电连接技术概览,PACK,电气连接形式,FUSE,MSD,PDU,FUSE,动力电池系统电连接技术概览,实例,Cell,之间（方形电池）,Module,之间（方形电池）,Cell,之间（,圆柱形,电池）,Module,（圆柱形电池）,Cell,之间（软包电池）,Module,（软包电池）,动力电池系统电连接技术概览,新能源汽车免费大课堂,Fuse,保护逻辑是模组的损坏不能导致,Cell,损坏，无论是模组的还是,cell,的损坏不能导致,pack,的损坏。,在危险电流值上，软件上的动作时间快于,pack.,7 mil Nickel strap material is necked down to 3.6 mm,and clears at approximately,21,00A in,0.1,sec,.,动力电池系统电连接技术概览,1,影响,Busbar,/,高压导线的载流因子,2,Busbar,/,高压导线计算选型方法,3,Busbar,/,高压导线测试标准和方法,4,铜铝连接技术,5,Pack,电气安全,设计,6,导线,实际,载流：,I=I,n,f,1,f,2,f,3,f,4,I,n,：导线额定载流,f,1,:,环境温度升高对载流的影响,f,2,:,导体温度升高对载流的影响,f,3,:,多心线对载流的影响,f,4,:,频率增加对载流的影响,来自,图片来自,来自,集肤,效应,当任意大导体对磁场交变时，这种导体就会感应电流，产生涡流现象。,f1,f2,f3,f4,图片,来自,影响,Busbar,/,高压导线的载流因子,束缚数,1,2,3,4,5,6-7,8-10,11-12,折算,1,0.8,0.7,0.6,0.55,0.5,0.45,0.4,集肤效应,多芯线,影响,Busbar,/,高压导线的载流因子,新能源汽车免费大课堂,汇流排实际载流,注：表中分数的分子表示交流负荷，分母表示直流负荷,。,影响汇流排载流的因数：,F1:,集肤效应；,F2,母线,平放安装时,，,载,流应该小于竖直安装；,F3,汇流排表面有无绝缘层。,集肤效应,安装方向,表面包裹,厚度,宽度,动力电池系统电连接技术概览,1,影响,Busbar,/,高压导线的载流因子,2,Busbar,/,高压导线计算选型方法,3,Busbar,/,高压导线测试标准和方法,4,铜铝连接技术,5,Pack,电气安全,设计,6,方法一，根据温升曲线,-,具体导线特性,Busbar,/,高压导线计算选型方法,序号,用电设备,额定电流,峰值电流,峰值时间,1,电池组,235A,468A,30S,2,电机控制器,182A,416A,30S,3,电机,263A,500A,30S,4,DC-DC/,充电器,18,5,PTC,12A,21A,30S,6,压缩机,6A,7.5A,30S,7,快充,250A,其中，,MCUPDU,线束，,额定电压,405V,，额定电流,182A,，峰值电流,416A,，绝缘体允许最高温度,125,，峰值电流持续时间,30S,某项目的电流电压值如下：,方法二，,计算公式,Busbar,/,高压导线计算选型方法,材料,铜,传热系数,5,W/(m,2,K),环境温度,25,C,截止温度,60,C,宽,a,30,mm,厚,b,2,mm,额定电流,186.96,A,峰值电流,400,A,峰值电流持续时间,30,s,温度,31.49,C,某项目,温升要求，当通入额定,185A,电流时，铜排温升不能超过,35,，排长度,140mm,相关,其他,数值如下：,仿真结果,条件：初始温度,25,，额定电流,185A,，铜排规格：,30*2,；,结论：最高温度：,47.228,，温升为,22.228,，满足设计需求,实验测试,结果：,条件：室温,28.1,，额定电流,185A,，通电时间,70min,；,结论：硬铜排温升,-13.8,软,铜排温升,-19.3,满足,185A,恒定电流情况下温升不超,35,要求。,a,b,l,根据上式计算出横截面是,53.4,平方毫米，取整,60.,方法三，经验表,25,铜铝载流（来自国家电工手册）,铝导线,横截面积,2.5,4,6,10,16,25,35,45,70,95,120,150,185,有绝缘层,载流（,A),10,20,30,50,64,100,105,135,175,238,240,300,370,铝排,载流（,A),15,30,45,75,96,150,158,203,263,356,360,450,555,铜导线,有绝缘层,载流（,A),20,30,50,64,100,105,135,175,238,240,300,370,铜排,载流（,A),30,45,75,96,150,158,203,263,356,360,450,555,Busbar,/,高压导线计算选型方法,例：某电池包,动力电池,高压,输出线,额定电流,235A,，额定电压,405V,。,铜牌：可以选,45mm,，选,15,3,的铜排；,铝排：,可以,选,70mm,，,选,25,3,的铜排。,横截面积,硬铜排温升实验测试（,60mm,）,时间（,min）,位置,1,位置,2,位置,3,0,28.1,28.1,28.2,5,29.8,34,34.3,10,29.5,36,36.4,15,29.7,37.2,37.4,20,30.8,38.1,38.3,25,31,38.9,38.7,30,31,39.1,39.1,35,30.6,39.6,39.2,40,31.2,40.2,39.6,45,31.3,40.2,39.3,50,31.2,40,39.3,55,31.3,41.4,40.1,60,30.9,41.4,40.8,65,31.1,41.5,40.5,70,31,41.9,40.4,软铜排温升实验测试（,60mm,）,时间（,min）,位置,1,位置,2,位置,3,0,28.1,28.1,28.3,5,29.6,34.2,32.8,10,31.4,37,35.4,15,30.7,38.5,37.4,20,31.1,39.5,38.2,25,30.2,41.5,39,30,31.6,42.4,41.1,35,32,42.5,41.5,40,31.2,44,42.8,45,31.1,44.1,41.8,50,31.5,44.5,42.4,55,31.7,45.8,42.9,60,31.3,47.2,44.4,65,31.2,47,44.1,70,30.1,47.4,44.9,铜排内阻统计,图纸编号,内阻（,m,）,ATEV.8000-02,0.1732,ATEV.8000-03,0.1854,ATEV.8000-04,0.1304,ATEV.8000-05,0.0907,ATEV.8000-06,0.3126,ATEV.8000-07,0.321,ATEV.8000-08,0.1207,ATEV.8100-05,0.235,ATEV.8100-06,0.0693,ATEV.8100-07,0.1305,ATEV.8100-08,0.101,ATEV.8100-09,0.0782,ATEV.8100-10,0.0794,ATEV.8100-11,0.1582,铜排温升测试,位置,1,位置,2,位置,3,位置,1,位置,2,位置,3,Busbar,/,高压导线计算选型方法,计算好需要实际验证,硬铜排测试条件：,185A,恒流放电（,70min,）,硬铜排温升：,13.8,合格温升：,35,结论,：,合格,软铜排测试条件：,185A,恒流放电（,70min,）,硬铜排温升：,19.3,合格温升：,35,结论：,合格,内阻测试,内阻测试,动力电池系统电连接技术概览,1,影响,Busbar,/,高压导线的载流因子,2Busbar,/,高压导线计算选型方法,3,Busbar,/,高压导线测试标准和方法,4,铜铝连接技术,5,Pack,电气安全,设计,6,来自,USCAR 21,及,LV214,来自,DELPHI test report,线束相关标准,AK SR215,LV214,LV216,USCAR 21-1,USCAR25,USCAR37,ISO6722,BS EN60512-5-2,BS,EN60512-5-1,其他企业相关标准,VW60306,PSA B25 1140,GWM 15626,FORD EX-XU5T-1A303-AA,BENZ MBN 10308-1,NISSAN 2420NDS03机械,电气,环境,Busbar,/,高压导线测试标准和方法,GME,3191 4,.,25,试验后,，,拉力,合格，电压降或截面合格,震动,温度,盐雾,微电阻,耐压,拉拔力,恒温恒湿,动力电池系统电连接技术概览,1,影响,Busbar,/,高压导线的载流因子,2,Busbar,/,高压导线计算选型方法,3,Busbar,/,高压导线测试标准和方法,4,铜铝连接技术,5,Pack,电气安全,设计,6,铜,/,铝连接注意,事项,干燥环境，否则，产生铜绿,Cu,2,(OH),2,CO,3,铜,铝,铝,铝,Al,2,O,3,铜,镍,锡,镍,铝,锡,铜,铜,方案一：在模组出线端，用铜铝过渡排连接。,模组,方案二：在模组出线端，用铝排镀锡。,Au,Pt,Hg,Ag,C,Cu,H,Pb,Fe,Zn,Al,Na,Li,1.69,1.2,0.85,0.8,0.74,0.52,0,-0.13,-0.41,-0.76,-1.66,-2.71,-3.02,来自,VW,实验室,金属电动序,铜铝连接技术,铜,/,铝性能参数对比,名称,铜排,铝排,原料,紫铜,T2,（,EN,ISO,ETP,）,99.9%,99.7%,纯铝（,1350,8000,系）,导电面积,S,1.6S,重量,100,60,热传导率,390,229,热膨胀系数,17.3,24.1,焊接,铜铜 激光焊,铝铝激光焊,铜铝 超声波焊,S,1.6S,铜铝连接技术,铝导线是未来的趋势,铜铝连接技术,一般来说，一辆车,0.3570mm,的,Cu,总长,1.9km,总重,28kg,一辆车,2.570mm,的,Al,总重,8.8kg,价格会降底,70%90%,动力电池系统电连接技术概览,1,影响,Busbar,/,高压导线的载流因子,2,Busbar,/,高压导线计算选型方法,3,Busbar,/,高压导线测试标准和方法,4,铜铝连接技术,5,Pack,电气安全,设计,6,电不安全在哪？,人体触电,mA,m,S,=350mA,人体电阻主要是皮肤电阻,，潮湿,情况下可降到,1,k,无感觉或微弱感觉,麻酥、针刺感、肌肉收缩,心室颤动、呼吸困难,来自德国大众培训,对于,任何,B,级电压电路的中的带电部件，都应为接触人员提供防护。,例：,Pack,电气安全设计,心脏起搏器,和其他植入身体的电子器件,Pack,电气安全设计,关键：导通起搏器电极,同样适用于其它一些植入体内的电子器件，比如脑起搏器，以及外部的医疗电子设备，比如胰岛素泵，助听器等等,预防性检查要包含与工作活动内容相关以及工作地点相关的信息。,等电位均衡线,一般选用,M8,的紧固螺栓,来自德国大众培资料,Pack,电气安全设计,两个不同的元件出现壳体短路，人意外接触到这两个元件，导致电路闭合。,绝缘电阻及实物,标准：,SAE J1766,及,ECE,R100,都要求,绝缘电阻,500/V,，或,GB18384.1,Pack,电气安全设计,2,，如果,V1V2,（说明负极对地绝缘电阻小），则在,V1,表处加一个已知的电阻,R0,，此时电压为,V2.,1,，先,测,如,V1,及,V,3,，绝缘电阻为：,Ri,R,R0,R,Ri,R,V1,V2,让我们来看看为什么这么测量？,例子：,高压,系统中电池总电压的最大值,为,384,V,，因此绝缘电阻至少为,500/V,384 V=192,k,。,绝缘电阻测试与校正,万用表测量与计算,Pack,电气安全设计,Power Supply or Pack Chassis Ground,Battery Positive and Battery Negative,Vehicle Positive and Vehicle Negative,Fulk,表直接,测量,Fluke 17B,Multimeter,Fluke 1507 Insulation Tester,常见测量值是,550M,BMS,电阻值校正,Initial Resistance Reading:,(without introduction of the decade box into the circuit),kOhms,(10000k expected),Connect the Decade box to Chassis and pack(+)for the first half,the Chassis to pack(-)for second half.,Resistance Box Setting,Chassis to Battery+,Expected,Chassis to Battery,1000,kOhm,(9,9,9,9,9,9),kOhm,1000kOhm,kOhm,500,kOhm,(4,9,9,9,9,9),kOhm,500kOhm,kOhm,100,kOhm,(0,9,9,9,9,9),kOhm,100kOhm,kOhm,50,kOhm,(0,4,9,9,9,9),kOhm,50kOhm,kOhm,10,kOhm,(0,0,9,9,99),kOhm,0kOhm,kOhm,RETURN decade box to(9,9,9,9,9,9)and disconnect it from the pack.,互锁,HVIL,高压互锁的目的是，用来确认整个高压系统的完整性的，当高压系统回路断开或者完整性受到破坏的时候，就需要启动安全措施,了,。（,US 7586722,）,三种信号输出：,1,，,12V,信号,传输,2,，加一个,LDO,用,5V,输出,3,，,PWM,输出，,1HZ,来自,TE,发生源,vcu,12V,12V,0S 1S 2S 3S 4S 5S T,Pack,电气安全设计,2009 Tyco Electronics,手动断开,-,紧急按钮,Pack,电气安全设计,目前做法都是,BMS,收到,CAN,信号切断高压。,但也有一些手动急停按钮，是一种物理开关，当遇到紧急情况，驾驶人按急停按钮，产生高,(,或低电平），,BMS,收到,高,电平（或低电平）时，关联继电器从而关断高压回路。,爬电距离与电气间隙,Pack,电气安全设计,电气间隙,爬电距离,GBT16935,上的描述：,IEC,60664-1,1.,确认耐压等级,2.,确认污染等级,3.,确认,CTI,值,4.,确认工作电压,5.,确认工作海拔高度,1,2,确认电气间隙,2,3,4,5,确认爬电距离,如果发生电解液的泄露，建议按下列的方法确定爬电距离：,IEC 60664-1,某,项目，,PACK,电压为,320V,则：,1,2500V,，,2,，电池包常见是等级,2,3,，,CTI450,，,4,，,320,，,5,，,2000,米,爬电距离：,2.2mm,电气间隙：,1.5mm,耐压,污染等级,海拔,2000,米,CTI,污染等级,GBT16935,某,项目，,PACK,电压为,320V,则：,爬电距离：,a)0.25*320+5=85mm,b)0.125*320+5=45mm,爬电距离,电气间隙,