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,153,的铜排；,铝排：可以选,70mm,，选,253,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,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,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,GME3191 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。