Reliability analysis of the module busbars of power battery systems

doi:10.19799/j.cnki.2095-4239.2024.0026

Abstract

Abstract:

With the continuous implementation of several global environmental awareness initiatives in recent years, new energy vehicles have gradually emerged as crucial areas of development within the global automobile industry. Furthermore, ensuring the safe operations of power batteries, which represent the core components of new energy vehicles, has become critical for the development of electric vehicles. Accordingly, numerous studies have investigated the thermal characteristics of power battery systems, primarily focusing on the power battery pack or battery module. However, when designing power battery pack structures, ensuring the thermal performance of busbars, which are critical connecting components, is also crucial. Motivated by this, the current study focuses on the development of modules within square power battery systems, considering the structural designs, strength analyses, and heat dissipation evaluations of busbars in such battery systems. Furthermore, it examines the reliability settings of process parameters and verifications of product reliability. Overall, the findings of the study are anticipated to guide the development of battery systems.

Key words: busbar, welding, temperature rise, reliability, battery systems

CLC Number:

TM 911

Xiaojun ZHAO, Yingchao WANG, Meng CHEN, Peng YANG, Zhanwang AN, Jianli LIU, Di WU. Reliability analysis of the module busbars of power battery systems[J]. Energy Storage Science and Technology, 2024, 13(7): 2450-2458.

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标准序	运行序	功率/W	速度/(mm/s)
13	1	5000	60
4	2	3500	60
1	3	3000	60
10	4	4500	60
12	5	4500	120
2	6	3000	90
5	7	3500	90
11	8	4500	90
8	9	4000	90
9	10	4000	120
3	11	3000	120
14	12	5000	90
7	13	4000	60
6	14	3500	120
15	15	5000	120

试验序号	功率/W	速度/(mm/s)	熔深/mm	熔宽/mm
1	5000	60	2	1.59
2	3500	60	0.78	1.28
3	3000	60	0.377	1.18
4	4500	60	1.63	1.63
5	4500	120	0.8	1.34
6	3000	90	0.35	0.82
7	3500	90	0.39	0.89
8	4500	90	1.29	1.39
9	4000	90	0.78	1.16
10	4000	120	0.42	1.05
11	3000	120	0.34	0.7
12	5000	90	1.66	1.47
13	4000	60	1.43	1.65
14	3500	120	0.37	0.91
15	5000	120	1.18	1.29

试验序号	功率/W	速度/(mm/s)	熔深/mm	熔宽/mm
1	5000	60	2	1.59
2	3500	60	0.78	1.28
3	3000	60	0.377	1.18
4	4500	60	1.63	1.63
5	4500	120	0.8	1.34
6	3000	90	0.35	0.82
7	3500	90	0.39	0.89
8	4500	90	1.29	1.39
9	4000	90	0.78	1.16
10	4000	120	0.42	1.05
11	3000	120	0.34	0.7
12	5000	90	1.66	1.47
13	4000	60	1.43	1.65
14	3500	120	0.37	0.91
15	5000	120	1.18	1.29

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