The principles of high voltage (HV) battery array design, which is based on existing, off-the-shelf Li-Ion batteries (e.g., certified Lithium 6T Batteries), is presented. The battery array includes, besides the series connected battery modules, an HV switch controlled by a controller unit and additional safety components. The paper first reviews all the safety hazards associated with Li-Ion batteries and HV systems which generate design requirements and constraints. Then the basic design together with the principal components are described.
Citation: O. Kost, “Connecting Standard Li-Ion Batteries in Series to Form a High Voltage Array,” In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 11-13, 2026.