With the rising adoption of electric vehicles (EVs), the need for robust and efficient power distribution systems has become increasingly important. This paper outlines a strategic method for selecting switchgear and busbars in EV battery packs, emphasizing key factors such as safety, energy efficiency, thermal control, and future scalability. Proper optimization of these components can significantly improve performance, minimize power losses, and ensure durability under demanding operating conditions.
The design and selection of battery conducting components, such as switchgears and busbars, are typically based on the maximum continuous and peak current capabilities of the EV battery pack. While this approach ensures that the components can withstand extreme conditions, it often leads to over-engineering, resulting in unnecessary costs and added weight. However, this method overlooks the dynamic power demands of the vehicle, which fluctuate based on driving conditions and usage. Real-time heat generation is directly affected by these varying demands, highlighting the need to incorporate factors like thermal performance and efficiency in the design process to optimize component size and functionality.
This paper investigates various approaches to sizing critical components, including battery busbars, fuses, contactors, and pre-charge resistors, within high-voltage battery packs. It explores how these components are tailored to meet the power demands and operational conditions of electric vehicles (EVs). The study also addresses the thermal behaviour of these components, emphasizing heat generation, dissipation, and the implementation of cooling strategies to ensure optimal performance. In addition, it analyzes how protection devices are coordinated to effectively handle issues such as overloads and short circuits, thereby enhancing the safety, operational efficiency, and longevity of the battery pack.