Bolted busbar joint

Example

Use in Lemonergy

Make series/parallel architecture explicit.

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Connected concepts

Related concepts from the knowledge graph. Connections show context, not cause and effect. Hover or focus a linked term for its definition.

Busbar

A rigid copper or aluminium conductor that joins cell terminals into series and parallel groups, and modules into the pack. Its cross-section is sized for current and heating, and its joints — welded or bolted — are a classic source of resistance and failure.

Electrical contact resistance

The extra resistance where two conductors touch, because current passes only through microscopic contact spots and any oxide film on them. It falls with contact force and good plating and rises with corrosion and fretting. At 300 A a joint of 50 µΩ dissipates 4.5 W, enough to overheat a poorly cooled connection.

Laser welding

Joining metal with a focused laser beam, used to seal cans, attach caps and connect busbars to cell terminals. It is fast and precise but sensitive to gaps and reflectivity, so copper joints need special wavelengths or beam shaping.

Remanufacturing and repair

Restoring a pack to its original duty by replacing failed or weak modules, cells, electronics or seals, then retesting it. It keeps the most value of any end-of-life route, and depends on packs that can be opened and on cells that can be matched.

Terminal

The external conductor through which current enters and leaves the cell: the can and cap of a cylindrical cell, two posts on a prismatic cell, or the sealed foil tabs of a pouch cell.

References & further reading

Further reading on this topic

These sources provide broader context; they are not presented as citations for every statement in this entry.

1. Extended Kalman filtering for battery management systems of LiPB-based HEV battery packs: Part 2. Modeling and identification

   Gregory L. Plett · Journal of Power Sources · 2004

   Topic background · Battery charge balance, open-circuit voltage, ohmic loss, polarization dynamics and model identification; parameters require cell-specific data.

2. Getting Started with the BQ76925

   Texas Instruments · 2019

   Topic background · A concrete BMS analog front-end example: cell voltage, current, temperature measurement and MCU integration.