A Strategic Approach to the Selection of Switchgear and Busbars for EV Battery Packs Tata Motors, Limited

Format:

Book

Conference/Event

Author/Creator:

Soman, Anu, author.

Contributor:

K, Mathankumar

satheesh, Goutham

Conference Name:

Symposium on International Automotive Technology (2026) (2026-01-28 : Pune, India)

Language:

English

Physical Description:

1 online resource cm

Place of Publication:

Warrendale, PA SAE International 2026

Summary:

With the rising adoption of electric vehicles, the need for robust and efficient power distribution systems has become increasingly important. As the battery pack is the primary energy source for an electric vehicle (EV), the strategy of selection of switchgears and busbars is paramount. Currently, the design and selection of battery protection and conducting components, such as switchgears and busbars are carried out primarily focusing on the continuous current and the peak current capabilities of the battery pack. Despite this approach ensuring that the components can withstand extreme conditions, it often results in over-engineering. The sizing should be such that it does not overdesign, which would result in unnecessary cost and material weight addition to the pack, ultimately leading to performance deterioration. As the current discharge from a battery pack is dynamic in nature and fluctuates based on driving conditions and usage a real-time heat generation studies have to be carried out based on this varying demand. This paper explores various sizing strategies for selecting key components such as busbars, fuses, contactors, relay and pre-charge resistor in a high voltage battery pack. It also focuses on the thermal behaviour of these electrical components, especially the busbar, including heat generation and dissipation under the implemented cooling strategies. A thermal simulation study was carried out on ANSYSTM platform to investigate the thermal behaviour of busbars under varying load current. An investigatory study is carried out on the sizing of electrical components for a 96V battery pack system, considering thermal behaviour and protection coordination

Notes:

Vendor supplied data

Publisher Number:

2026-26-0165

Access Restriction:

Restricted for use by site license