Modular high-performance battery systems

Online Editor

AKASOL’s innovative battery systems are used in electric and hybrid utility vehicles for passenger and freight transportation on roads, railways and waterways, as well as in industry. Innovative visions and a passion for creating alternative drive concepts are the foundation of their success. Today their products are an integral part of the design concepts of some of the world’s leading utility vehicle manufacturers.

Developing a high-performance, modular OEM battery system called for a highly powerful, robust and reliable pluggable connection solution that was also extremely safe and had the necessary certification for use in the automotive industry.

Stäubli worked jointly with AKASOL to configure a solution based on the modular Stäubli CombiTac system, flexible enough to support a 30% increase in the battery design’s performance even without any design modifications. Stäubli also implemented the connection with pre-assembled cables according to the specifications of AKASOL’s OEM customer.

These connections, which carry current as well as data signals between the individual battery modules and to the power electronics, allow for safe battery maintenance operations. Simply unplugging the power module from the battery enables technicians to work safely with no live voltage. Therefore, it’s possible to change fuses without the need for an electrician or additional safety staff. This solution ensures that there is absolutely no voltage at the power module. The modular connections also ensure fast, safe connections during assembly of the individual battery layers. Thanks to its robust design, the high-quality CombiTac solution can even stand up to strong vibrations in continuous operation. At the customer’s request, an additional circuit board for monitoring was built into the power electronics with the CAN bus as part of the safety technology. This is another area of Stäubli’s expertise, making the solution even safer.

The CombiTac connector system impressed the engineers at AKASOL with its proven reliability and robustness. The Stäubli team also offered flexibility and expertise in implementing the additional technical specifications and strict safety requirements of the international utility vehicle manufacturer. The user-specific cable solution allows for safe and efficient assembly of battery modules. Stäubli’s safe connector solution in the high-performance battery systems guarantee continuous, long-lasting electric vehicle operation and the highest level of safety for maintenance work.

Dorothée Kössler is with Stäubli

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