In this page, methods of keeping a battery module electrically isolated from the rest of the car will be discussed.
(Up to this point), I couldn’t find any content exactly on keeping a battery module electrically isolated. What I have found about electrical isolation can be summed up with the following:
Keep live wires away from locations where they can make contact with other components and/or hands
Any exposed conductors should not be connected to the electrical system
Keep wires from fraying/leaking
In general, keep a layer of insulating material between conductors
The regulations state that for our battery module,
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Here are some pieces of practical knowledge I have gathered from the MSXIV documentation
Wires:
Wiring runs for voltage taps should be kept as short and bound together as much as possible to minimize wires rubbing and the possibility that the insulation will wear
Wires should have some form of strain relief to keep them from wearing, e.g. rubbery glue, as done in Wire Guide Under PCB Module - Mechanical - Confluence (atlassian.net).
Tip from MSXIV: If you’re doing right-angle crimps, use https://www.digikey.ca/en/products/detail/te-connectivity-amp-connectors/61481-1/294358
To be avoided
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Connecting Modules in Series: Battery Module Rev 5 - Mechanical - Confluence (atlassian.net):
Used electrically insulating sleeve washers on both ends of the hookup nut & bolt
Hard fiber sleeves
Disk springs made of stainless steel to keep the pieces pressed together
Hookup was not in contact with busbar
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