On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar

High-voltage busbars are important electrical components in today’s electric vehicle battery systems. Mechanical deformations in the event of a vehicle crash could lead to electrical busbar failure and hazardous situations that pose a threat to people and surroundings. In order to ensure a safe appl...

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Autores principales:	Tobias Werling, Georg Baumann, Florian Feist, Wolfgang Sinz, Christian Ellersdorfer
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	busbar split Hopkinson pressure bar dynamic compression crashworthiness insulation failure battery safety Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
Acceso en línea:	https://doaj.org/article/13189e8069974a7a8980d46fe1458812
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spelling	oai:doaj.org-article:13189e8069974a7a8980d46fe14588122021-11-11T17:53:20ZOn the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar10.3390/ma142163201996-1944https://doaj.org/article/13189e8069974a7a8980d46fe14588122021-10-01T00:00:00Zhttps://www.mdpi.com/1996-1944/14/21/6320https://doaj.org/toc/1996-1944High-voltage busbars are important electrical components in today’s electric vehicle battery systems. Mechanical deformations in the event of a vehicle crash could lead to electrical busbar failure and hazardous situations that pose a threat to people and surroundings. In order to ensure a safe application of busbars, this study investigated their mechanical behavior under high strain rate loading using a split Hopkinson pressure bar. Two different types of high-voltage busbars, consisting of a polyamide 12 and a glass-fiber-reinforced (30%) polyamide 6 insulation layer, were tested. Additionally, the test setup included a 1000 V electrical short circuit measurement to link the electrical with the mechanical failure. It was found that the polyamide 12 insulated busbars’ safety regarding insulation failure increases at high loading speed compared to quasi-static measurements. On the contrary, the fiber-reinforced polyamide 6 insulated busbar revealed highly brittle material behavior leading to reduced bearable loads and intrusions. Finally, the split Hopkinson pressure bar tests were simulated. Existing material models for the thermoplastics were complemented with an optimized generalized incremental stress state-dependent model (GISSMO) with strain rate dependency. A good agreement with the experimental behavior was achieved, although the absence of viscoelasticity in the underlying material models was notable.Tobias WerlingGeorg BaumannFlorian FeistWolfgang SinzChristian EllersdorferMDPI AGarticlebusbarsplit Hopkinson pressure bardynamic compressioncrashworthinessinsulation failurebattery safetyTechnologyTElectrical engineering. Electronics. Nuclear engineeringTK1-9971Engineering (General). Civil engineering (General)TA1-2040MicroscopyQH201-278.5Descriptive and experimental mechanicsQC120-168.85ENMaterials, Vol 14, Iss 6320, p 6320 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	busbar split Hopkinson pressure bar dynamic compression crashworthiness insulation failure battery safety Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
spellingShingle	busbar split Hopkinson pressure bar dynamic compression crashworthiness insulation failure battery safety Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85 Tobias Werling Georg Baumann Florian Feist Wolfgang Sinz Christian Ellersdorfer On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar
description	High-voltage busbars are important electrical components in today’s electric vehicle battery systems. Mechanical deformations in the event of a vehicle crash could lead to electrical busbar failure and hazardous situations that pose a threat to people and surroundings. In order to ensure a safe application of busbars, this study investigated their mechanical behavior under high strain rate loading using a split Hopkinson pressure bar. Two different types of high-voltage busbars, consisting of a polyamide 12 and a glass-fiber-reinforced (30%) polyamide 6 insulation layer, were tested. Additionally, the test setup included a 1000 V electrical short circuit measurement to link the electrical with the mechanical failure. It was found that the polyamide 12 insulated busbars’ safety regarding insulation failure increases at high loading speed compared to quasi-static measurements. On the contrary, the fiber-reinforced polyamide 6 insulated busbar revealed highly brittle material behavior leading to reduced bearable loads and intrusions. Finally, the split Hopkinson pressure bar tests were simulated. Existing material models for the thermoplastics were complemented with an optimized generalized incremental stress state-dependent model (GISSMO) with strain rate dependency. A good agreement with the experimental behavior was achieved, although the absence of viscoelasticity in the underlying material models was notable.
format	article
author	Tobias Werling Georg Baumann Florian Feist Wolfgang Sinz Christian Ellersdorfer
author_facet	Tobias Werling Georg Baumann Florian Feist Wolfgang Sinz Christian Ellersdorfer
author_sort	Tobias Werling
title	On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar
title_short	On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar
title_full	On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar
title_fullStr	On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar
title_full_unstemmed	On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar
title_sort	on the dynamic electro-mechanical failure behavior of automotive high-voltage busbars using a split hopkinson pressure bar
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/13189e8069974a7a8980d46fe1458812
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On the Dynamic Electro-Mechanical Failure Behavior of Automotive High-Voltage Busbars Using a Split Hopkinson Pressure Bar

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