Manual service disconnect for a battery system
An interconnect is disclosed that opens a battery circuit when an access cover is removed. The interconnect includes a single installed position, and does not include any throw positions to avoid ambiguity. The interconnect includes a conductive element that closes the battery circuit when the interconnect is installed. The access cover cannot be removed when the interconnect is installed, because the interconnect includes at least one mechanical feature that prevents removal of the access cover. In some instances, the interconnect is integrated into the access cover, such that when the cover is removed, the circuit is opened necessarily during removal. The interconnect interface may include blades, pins, or other electrically conducting elements. The interconnect is arranged in the battery system away from power electronics and other components that may interface to an electrical load, thus providing an added measure of safety when the access cover is off.
1 . An apparatus comprising:
a first plurality of battery modules in a pack and a second plurality of battery modules in the pack, wherein the battery modules of the first and second pluralities of battery modules each comprise a plurality of batteries;
a socket comprising:
a first electrical terminal coupled to the first plurality of battery modules in the pack; and
a second electrical terminal coupled to the second plurality of battery modules in the pack; and
a disconnect configured to be arranged in the socket, wherein the disconnect, when removed from the socket, decouples the first plurality of battery modules from the second plurality of battery modules to reduce a voltage in the pack.
2 . The apparatus of claim 1 , wherein the disconnect is arranged at an intermediate node between the first plurality of battery modules and the second plurality of battery modules.
3 . The apparatus of claim 1 , further comprising a housing to which the first plurality of battery modules and the second plurality of battery modules are coupled.
4 . The apparatus of claim 1 , wherein the disconnect is further configured to be installed to:
couple the first plurality of battery modules with the second plurality of battery modules to increase the voltage in the pack to at least 400V at a power conditioning unit.
5 . An interconnect socket for interrupting a plurality of battery modules of a battery system, wherein the battery modules of the plurality of battery modules each comprise a plurality of batteries, the interconnect socket comprising:
a first electrical terminal coupled to a first plurality of battery modules and arranged at an intermediate node; and
a second electrical terminal coupled to a second plurality of battery modules and arranged at the intermediate node, wherein:
the interconnect socket is configured to receive a disconnect in a single installed position; and
in the single installed position, the disconnect electrically connects the first plurality of battery modules to the second plurality of battery modules in series.
6 . The interconnect socket of claim 5 , wherein, when installed, the disconnect electrically couples the first electrical terminal to the second electrical terminal.
7 . The interconnect socket of claim 5 , wherein the disconnect comprises an insulative body and a conductive path, and wherein, when in the single installed position, the conductive path is arranged electrically in series with the first electrical terminal to the second electrical terminal.
8 . The interconnect socket of claim 7 , wherein, when the disconnect is in the single installed position, the insulative body prevents outside access to the plurality of batteries.
9 . The interconnect socket of claim 5 , wherein the interconnect socket is affixed to a housing configured to house the plurality of battery modules.
10 . The interconnect socket of claim 5 , wherein:
when in the single installed position, a first maximum voltage is achieved in the battery system; and
when uninstalled, a second maximum voltage less than the first maximum voltage is achieved.
11 . The interconnect socket of claim 10 , wherein the intermediate node is mid-pack, and wherein the second maximum voltage is about half of the first maximum voltage.
12 . A method of connecting and interrupting a plurality of battery modules of a battery system, wherein the battery modules of the plurality of battery modules each comprise a plurality of batteries, the method comprising:
achieving a first maximum voltage when a disconnect is installed in a socket arranged at an intermediate node of the plurality of battery modules, wherein the socket comprises a first electrical terminal coupled to a first plurality of battery modules of the battery system and a second electrical terminal coupled to a second plurality of battery modules of the battery system; and
achieving a second maximum voltage less than the first maximum voltage when the disconnect is removed from the socket.
13 . The method of claim 12 , wherein achieving the first maximum voltage comprises installing the disconnect to couple the first plurality of battery modules with the second plurality of battery modules.
14 . The method of claim 12 , wherein achieving the first maximum voltage comprises blocking access to the plurality of battery modules, and wherein achieving the second maximum voltage comprises unblocking access to the plurality of battery modules.
15 . The method of claim 12 , wherein achieving the second maximum voltage comprises removing the disconnect to decouple the first and second pluralities of battery modules from each other.
16 . The method of claim 12 , wherein achieving the first maximum voltage comprises engaging the disconnect with the socket in a single installed position.
17 . The method of claim 12 , wherein the intermediate node is mid-pack such that the second maximum voltage is about half of the first maximum voltage when the disconnect is installed.
18 . The apparatus of claim 1 , wherein:
the first plurality of battery modules comprises at least four battery modules arranged linearly from an interface to the first electrical terminal of the socket; and
the second plurality of battery modules comprises at least four battery modules arranged linearly from the interface to the second electrical terminal of the socket.
19 . The apparatus of claim 1 , wherein the first and second electrical terminals comprise latching features configured to engage with the disconnect.
20 . The apparatus of claim 1 , wherein the disconnect is arranged in the socket with a quarter-turn lock mechanism.