Abstract: An off-board battery charger for a vehicle may include a high-voltage connector having first, second and power supply connector ports. The first connector port connects to a vehicle controller via a first cable. The second connector port connects to a vehicle battery via a second cable. And, the power supply connector port is electrically connected with the second port and receives power via a power supply cable from a separate and external power supply.

Abstract: An integrated cell separator/high voltage bus bar carrier assembly for a high voltage traction battery includes a cell separator having a plurality of cell separator walls and a plurality of bus bar retention walls carried by the plurality of cell separator walls. A high voltage bus bar is carried by the plurality of bus bar retention walls of the cell separator.

Abstract: A charging system for a high voltage battery includes a pair of contactors each electrically connected to one of positive and negative terminals of the battery and configured to enable charging of the battery when closed; and a controller programmed to generate a notification indicating that one of the contactors is welded closed based on port voltage values achieved while issuing a predetermined sequence of open and close commands to the contactors after charge completion.

Abstract: An off-board battery charger for a vehicle may include a high-voltage connector having first, second and power supply connector ports. The first connector port connects to a vehicle controller via a first cable. The second connector port connects to a vehicle battery via a second cable. And, the power supply connector port is electrically connected with the second port and receives power via a power supply cable from a separate and external power supply.

Abstract: An example contactor weld detection method for an electric vehicle includes detecting that a contactor is welded closed when the contactor is commanded closed.

Abstract: A battery discharge device according to an exemplary aspect of the present disclosure includes, among other things, a sensor configured to sense a parameter of a high voltage source, a controller in communication with the sensor and a discharge circuit that discharges energy stored on the high voltage source in response to a command signal from the controller. The discharge circuit includes a plurality of resistors connected in parallel to one another.

Abstract: Methods and apparatus for assembling a high voltage battery without exposing an operator to contacts having a voltage greater than a predetermined maximum are presented. A bus bar module has standard compartments equipped with integrated bus bars separated by break compartments without bus bars. The bus bar module can be coupled to a plurality of electrochemical cells to connect the cells in groups having a voltage less than a predetermined maximum Vmax. Compartment lids can be closed to prevent contact with connected posts. A separate non-integrated bus bar can be provided to a break compartment to connect a first group of cells with a second group of cells to form a series of connected cells that can provide a voltage greater than Vmax, to achieve a desired battery voltage. The bus bar module and methods of the invention can protect an operator during battery assembly or service.

Abstract: A traction battery includes a housing that has a tray and a cover, and a plurality of battery components supported by the tray and enclosed by the cover. A service disconnect base is disposed within the housing and is electrically connected with the components by a circuit. The housing includes an access panel with a service disconnect plug attached to the panel. The access panel is movable between open and closed positions. The service disconnect plug connects circuitry within the service disconnect base when the panel is in the closed position. The service disconnect plug is disconnected with the service disconnect base when the panel is in the open position to open the circuit.

Abstract: An example battery cell for an electric vehicle includes at least one conductive case, and an electrode structure in direct electrical contact with the at least one conductive case. The electrode structure is to selectively provide power to an electric vehicle.

Abstract: An example contactor weld detection method for an electric vehicle includes detecting that a contactor is welded closed when the contactor is commanded closed.

Abstract: An integrated cell separator/high voltage bus bar carrier assembly for a high voltage traction battery includes a cell separator having a plurality of cell separator walls and a plurality of bus bar retention walls carried by the plurality of cell separator walls. A high voltage bus bar is carried by the plurality of bus bar retention walls of the cell separator.

Abstract: A battery discharge device according to an exemplary aspect of the present disclosure includes, among other things, a sensor configured to sense a parameter of a high voltage source, a controller in communication with the sensor and a discharge circuit that discharges energy stored on the high voltage source in response to a command signal from the controller. The discharge circuit includes a plurality of resistors connected in parallel to one another.

Abstract: An integrated contactor/service disconnect assembly according to an exemplary aspect of the present disclosure includes, among other things, a stationary contact, a movable contact selectively movable relative to the stationary contact and a service disconnect unit configured to block the movable contact from contacting the stationary contact.

Abstract: Methods and apparatus for assembling a high voltage battery without exposing an operator to contacts having a voltage greater than a predetermined maximum are presented. A bus bar module has standard compartments equipped with integrated bus bars separated by break compartments without bus bars. The bus bar module can be coupled to a plurality of electrochemical cells to connect the cells in groups having a voltage less than a predetermined maximum Vmax. Compartment lids can be closed to prevent contact with connected posts. A separate non-integrated bus bar can be provided to a break compartment to connect a first group of cells with a second group of cells to form a series of connected cells that can provide a voltage greater than Vmax, to achieve a desired battery voltage. The bus bar module and methods of the invention can protect an operator during battery assembly or service.

Abstract: A device for preventing electrical shorting between positive and negative terminals of a wiring harness includes a clip securable to conductors of the harness, a wall extending from the clip to be positioned between first and second terminals of the conductors when the clip, and a shield attached to the clip and movable between a first position wherein it blocks contact between a tool and the first terminal while allowing contact between the tool and the second terminal, and a second position wherein it blocks contact between the tool and the second terminal while allowing contact between the tool and the first terminal.

Abstract: A vehicle power system includes an electrical power source, an electrical bus, and a contactor electrically connected with the electrical power source and electrical bus. The contactor includes first and second poles, dual plungers each operatively associated with one of the first and second poles, and an electromagnetic coil configured to cause at least one of the dual plungers to move if the coil is energized.

Abstract: A device for preventing electrical shorting between positive and negative terminals of a wiring harness includes a clip securable to conductors of the harness, a wall extending from the clip to be positioned between first and second terminals of the conductors when the clip, and a shield attached to the clip and movable between a first position wherein it blocks contact between a tool and the first terminal while allowing contact between the tool and the second terminal, and a second position wherein it blocks contact between the tool and the second terminal while allowing contact between the tool and the first terminal.

Abstract: A vehicle power system includes an electrical power source, an electrical bus, and a contactor electrically connected with the electrical power source and electrical bus. The contactor includes first and second poles, dual plungers each operatively associated with one of the first and second poles, and an electromagnetic coil configured to cause at least one of the dual plungers to move if the coil is energized.

Abstract: A vehicle power system includes an electrical power source, an electrical bus, and a contactor electrically connected with the electrical power source and electrical bus. The contactor includes first and second poles, dual plungers each operatively associated with one of the first and second poles, and an electromagnetic coil configured to cause at least one of the dual plungers to move if the coil is energized.

Abstract: A vehicle may include an electric machine, a battery, a driver interface and one or more controllers. The one or more controllers may be configured to determine whether a battery imbalance condition exists, to cause an alert to be generated via the driver interface if a battery imbalance condition exists, to determine whether a response to the alert is received, and to cause the battery to be rebalanced in a single cycle if a response to the alert is received.