1. Key points of anti-short circuit structure design
The anti-short circuit structure of the battery box is crucial. First of all, sufficient isolation space should be ensured in the layout of the positive and negative electrodes of the battery. For example, an insulating partition is used to completely separate the positive and negative electrode areas. The material of the partition must have high insulation, high temperature resistance and high mechanical strength, such as high-quality engineering plastics or ceramic materials. In the design of the battery fixing slot, it is necessary to ensure that the positive and negative electrodes will not contact due to shaking after the battery is installed. The dimensional accuracy of the slot must be strictly controlled, and the tolerance range should be within a very small range, so that the battery can be tightly and stably fixed. At the same time, the circuit layout inside the battery box should also be reasonable to avoid short circuits caused by crossing or damage of the lines. For example, wire troughs or harness protective covers are used to arrange the wires in an orderly manner, and the insulation sheath of the wires must comply with relevant safety standards and have sufficient thickness and wear resistance.
2. Safety performance verification method-electrical test
Electrical testing is a key link to verify the anti-short circuit safety performance of the battery box. First, conduct an insulation resistance test. Use an insulation resistance tester to apply a specified voltage between the positive and negative poles of the battery box and between the positive and negative poles and the shell, and measure its insulation resistance value. Generally, the insulation resistance value is required to be greater than several megohms to ensure good insulation performance. Then conduct a withstand voltage test, gradually increase the voltage to the specified withstand voltage value. For example, for some low-voltage battery boxes, the withstand voltage value can be set at hundreds of volts for a certain period of time to observe whether there is a breakdown phenomenon. Short-circuit testing is also an important verification method. The positive and negative poles of the battery box are directly short-circuited to monitor the size and duration of the short-circuit current. At the same time, check whether the battery box has abnormal phenomena such as overheating, smoking, and fire. A qualified battery box should be able to cut off the circuit in a short time, limit the short-circuit current, and prevent danger.
3. Safety performance verification method-environmental simulation test
In addition to electrical testing, environmental simulation testing can further verify the short-circuit safety performance of the battery box under different working conditions. During the high temperature test, the battery box is placed in a high temperature box and the temperature is set at the specified upper limit, such as 60℃ or even higher. After several hours, the electrical performance test and appearance inspection are carried out to see whether the insulation material is aged or the structure is deformed due to the high temperature, which may cause a short circuit risk. The low temperature test is the opposite. The temperature is reduced to the lower limit, such as -20℃, and the battery box performance is also evaluated after the test. In addition, a humidity test is also required. In a high humidity environment, such as a relative humidity of more than 90%, after a certain period of time, check whether there is water accumulation inside the battery box, short circuit hazards, and whether the outer shell and insulating parts are deformed due to moisture.
4. Continuous improvement and monitoring
Based on the results of safety performance verification, the anti-short circuit structure of the battery box is continuously improved. If a short circuit risk is found in a certain link during the test, such as the fixing method of the insulating partition is not firm enough, the design should be optimized in time, a more reliable fixing structure should be adopted, or additional protective measures should be added. At the same time, a monitoring mechanism should be established throughout the service life of the battery box to regularly check its safety performance. In particular, after the battery box has experienced collision, vibration or long-term use, the inspection frequency should be increased to ensure that its anti-short-circuit structure is always effective and its safety performance always meets the requirements, so as to ensure the safe and stable operation of the equipment or system using the battery box.
