Development of Busbar with New Locking Mechanism for High Voltage EV Battery Applications Mercedes-Benz R&D, Pvt., Limited

Format:

Book

Conference/Event

Author/Creator:

Venkatesh, Murali, author.

Contributor:

Bhramanna, Amol

Raghu, Arun

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:

In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also addresses heat generation issues associated with traditional screw-based connection. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency.This study presents the design methodology, performance analysis, and potential applications of the friction locking mechanism, demonstrating its advantages over conventional screwing methods in terms of thermal management, mechanical stability, and production efficiency. Post patent filing and concept approval, an iterative CAD-CAE loop was performed to refine and enhance the initial concept. Key takeaways from this process include critical material selection and potential design optimizations aimed at improving performance and manufacturing feasibility for series production implementation.The paper concludes with the results of prototype evaluations, rigorously tested against the current validation plan for series components to ensure compliance with required standards

Notes:

Vendor supplied data

Publisher Number:

2026-26-0155

Access Restriction:

Restricted for use by site license