With the wide application of battery technology, battery pack, as the core component of power and energy storage system, the design specification of its electrical parts is particularly important. Reasonable design of electrical parts is not only related to the performance and life of battery pack, but also directly affects the safety and reliability of the system. This paper systematically sorts out the design specifications of electrical components covering the conventional requirements of power battery pack and energy storage battery pack, aiming at providing comprehensive guidance for relevant design and manufacturing personnel and ensuring the stable operation of battery pack in practical applications.

I. Importance of battery pack electrical parts design

the electrical components in battery pack, including connected wiring harness, connectors, protection devices and sensors, undertake core functions such as current transmission, signal acquisition and safety protection. The formulation of design specifications can effectively avoid electrical faults, ensure the safety and stability of battery pack, and improve the overall performance of the system.

II. Basic principles of electrical parts design

1. security

electrical parts must ensure good insulation and short circuit resistance in various working environments to prevent potential safety hazards such as overheating and fire. The selection of materials shall conform to relevant standards of high temperature resistance and corrosion resistance.

2. Reliability

the design needs to ensure electrical connectionThe stability of connection and good vibration resistance and aging quality resistance ensure that the risk of poor electrical contact or fracture during long-term use is minimized.

3. Compatibility

electrical parts shall be highly matched with battery cells and battery management system (BMS) to ensure accurate signal transmission and stable current output, and meet the structural design requirements of battery pack at the same time.

4. Maintainability

the design should be convenient for daily maintenance and replacement, reduce maintenance difficulty and improve the availability and service life of the system.

III. Details of electrical parts design specifications

1. connected wiring harness design

(1) selection of wires: wires conforming to international certification standards (such as UL and IEC) shall be adopted, with excellent electrical conductivity and temperature resistance, and the temperature resistance grade shall not be lower than 105℃. Power battery pack the conductor with large cross-sectional area and low impedance is preferred, and the energy storage battery pack reasonably configure the cross-sectional area according to the capacity.

(2) wiring harness layout and fixing: wiring harness should be arranged reasonably to avoid crossing and winding and reduce electromagnetic interference. Through ties, buckle and other fixed measures to prevent abrasion and fracture caused by vibration.

(3) protective measures: use flame-retardant jacket or casing to protect the wiring harness to prevent mechanical damage and environmental corrosion and improve safety.

2. Connector Design

(1) specification selection: the connector shall meet the requirements of battery pack rated voltage and current and have sufficient safety margin. More than battery pack power connectors with high current and large specifications are used, and energy storage battery pack should be selected according to specific applications.

(2) protection level: the connector should have certain waterproof and dustproof ability, and it is recommended to reach IP54 or above level to adapt to complex environment.

(3) anti-loosening design: locking structure or anti-loosening device should be set to ensure reliable contact under vibration and impact conditions.

3. Protection Device Design

(1) over-current protection: configure appropriate fuse or circuit breaker according to battery pack rated current to prevent abnormal current from damaging the equipment.

(2) fuse box design: Fuse box should be easy to replace and detect, with good insulation performance and mechanical strength.

(3) voltage protection: cooperate with BMS to realize overvoltage and undervoltage protection to ensure that the battery monomer and overall voltage are within the safe range.

4. Sensor design

(1) temperature sensor: it is arranged in key parts of battery pack, and the sensor with fast response and high precision is selected to monitor temperature changes and timely warn of abnormalities.

(2) current sensor: monitor the charging and discharging current in real time to ensure the safe operation of the system according to the set parameters.

(3) voltage sensor: monitor monomer and total voltage to ensure the accuracy of battery pack voltage parameters and prevent abnormalities.

5. Grounding and insulation design

(1) grounding requirements: reasonably design grounding scheme to prevent static electricity accumulation and electrical interference and ensure system safety.

(2) insulation design: all electrical parts shall meet the requirements of insulation grade to prevent leakage and short circuit risks.

6. Identification and marking

all electrical parts shall be clearly marked, including voltage level, current specification, polarity, etc., which is convenient for installation and maintenance to avoid safety accidents caused by wrong connection.

IV. Design implementation and quality control

1. design review

the design of electrical parts shall be strictly reviewed to ensure compliance with specifications and practical application requirements. The review includes electrical performance, mechanical structure and safety protection.

2. Production Process control

in the production process, material selection and technological process should be strictly controlled to ensure stable quality of electrical parts and avoid performance degradation caused by technological problems.

3. Testing and verification

after completing the design and production, a number of verifications including insulation test, electric strength test test, vibration test, etc. shall be carried out to ensure that the electrical parts meet the design specifications and safety standards.