Thermal Modeling and Simulationwith High Voltage Solid StateRelays for Battery DisconnectionApplications : The potential of replacing mechanical contactors with semiconductors

Abstract: The swift shift of the automotive industry towards electrification is primarily propelled by technological advancements in battery technology. To stay competitive and meet the new demands of the industry, there is a crucial need for novel ideas and innovation. Higher energy density and lower cost makes Battery Electric Vehicles (BEV) competitive and affordable for a wider range of customers. Component space requirements inside a BEV as well as the growing trend towards increasing the voltage of the system from 400 V to 800 V poses new challenges that has to be overcome. Mechanical contactors have the advantage of being simple and easy to use, with low conductive losses. However, they have some drawbacks, such as poor performance when switching under load, limitedability to interrupt fault currents and large controlpower usage. To address these issues, a bidirectional MOSFET configuration can be used to replace the current system. This configuration provides enhanced abilities to quickly suppress fault current, improve robustness, eliminate mechanical failure points, and perform pre-charge sequences without the need for a dedicated branch. Additionally, this configuration maintains current performance in a smaller volume. Within the Battery distribution unit (BDU), this configuration replaces several components, such as thermal fuses, HV contactors, pre-charge relays,pre-charge resistors, and breaker/pyro-fuses with high voltage solid-state components. This study aims to propose potential mitigation methods through a combination of literature survey and comprehensive analysis using Simscape/-MATLAB Simulink models of a fully operational BDU utilizing readily available market components for a 1.2 kV system. The developed model illustrates the thermaland electrical performance of solid-state components in diverse testing scenarios, while maintaining their expected lifecycle. Additionally, sensitivity analysis is conducted using the proposed model to identify themost crucial design parameters within the system. The resulting system performs satisfactory during normal operations, albeit with ten times higher conductive losses attributed to the elevated junction resistance when compared to contactors.Consequently, additional cooling measures are required during harsh operations and DC fast charge. However, the required magnitization energy for a contactor does over time equate or even surpass the MOSFETs conductive losses. The design has established the feasibility of leveraging the primary switchfor pre-charge sequence execution, thus eliminating the need for a dedicated pre-charge branch. The system exhibits strong potential for interrupting both resistive and direct shorts at various locations in the model. However, the low system inductance and the need to avoid introducing any additional inductance into the system renders fault scenarios heavily dependent on said parameter. In conclusion, the proposed model exhibits considerable potential to eliminate numerous auxiliary components therefore reducing losses and offer a more adaptable and consolidated solution. Resulting in a smaller physical footprint and more favorable positioning within the BDU. Moreover, the financial analysis of the system highlights promising prospects for its integration into the drivetrain with the growingmarket trends.