Simulation methodologies to support novel fuse design for energy storage systems using COMSOL

The conventional fusing strategy for high current applications is to use potentially bulky and expensive cartridge fuses. In a typical battery pack configuration in a hybrid electric vehicle (HEV), one fuse can be required for each module, or additionally for each cell for double protection. As an example, a vehicle battery with several modules could require significant cost, weight and volume to protect itself using conventional cartridge fuses. The paper proposes the use of finite element modelling and simulation techniques in understanding the behaviour of novel fusing features that would need to be integrated into existing conductors safely. Accurate simulation reduces the need for real parts to characterise the performance of a given fuse design, hence speeding up the design process. Using a finite-element, multi-physics simulator, such as COMSOL, complex fuse designs with perforated features rather than traditional material thinning, aimed at providing structural stability, were used for the evaluation of the methodology. The paper shows validation of a conventional fuse design against the FE model and compares the behaviour of a conventional fuse design and busbar fuse, using modelled result. It also shows the equivalent thermal performance and structural performance analysis and demonstrates the effectiveness of using tools like COMSOL by comparing simulation results with experimental test data.