A Cost-Effective and Energy-Efficient Mechanical Contactor for 48V Electric Vehicles with Reconfigurable Battery Systems

This study investigates the feasibility of utilizing camshaft-driven contactor in 48 V battery systems for future electric vehicles (EVs). Most EV powertrains operate at high DC voltages, which introduces several challenges. These include high costs associated with safety regulations, increased component expenses for galvanic isolation requirements, isolation monitoring devices, and heightened safety risks. In contrast, the proposed 48 V design could reduce safety risks, lower production and maintenance costs, and simplify operation without compromising performance. The proposed Reconfigurable Battery System (RBS) integrates contactors designed to manage voltage differences between modules during operation. These contactors, of which the RBS requires a large number, are essential for maintaining system reliability and energy efficiency, as they minimize wear and losses during extended periods of non-use. Their quality is crucial to ensuring the overall reliability of the system. This paper presents a feasibility study of a camshaft-driven contactor design for RBS. The design was tested to assess its reliability and performance beyond the system's operational parameters. Experimental results, based on repeated engagement period testing under specific conditions and varying voltages, indicate promising outcomes.