High-voltage batteries consist of a network of individual battery cells, where the number of series-connected cells is significantly larger than the number of parallel-connected cells (s>>p). Understanding and controlling the short-circuit behavior of such systems is crucial for designing safe and efficient high-voltage battery pack systems. Applications aiming for operating voltages above 1500V may, depending on the cell chemistry, include more than 500 cells connected in series, whereas typically only a few cells are connected in parallel or no parallel connection exists at all (500s/1p). The resulting electrical network presents specific challenges regarding safety mechanisms and the management of short-circuit currents.

This poster presents an investigation of short-circuit currents in individual cells as well as in smaller series connections, which can be scaled for larger series configurations and thus serve as a model for larger systems.

A central aspect of this analysis is the influence of the internal resistance of the cells and cell interconnectors on the short-circuit behavior. At very high battery voltages, the internal resistance becomes significant due to the additive effect of cell contacts and connectors, which substantially impacts the system’s response to a short circuit.

The experimental setup for precise measurements of these currents is discussed. A specialized measurement environment, designed for both individual cells and smaller representative series configurations, is introduced. The experimental data are compared with impedance spectroscopy results to analyze the influence of internal resistance in various configurations.

In summary, this investigation provides valuable insights for the design and optimization of battery systems with high DC voltage. It supports the development of safe and efficient energy storage solutions that meet the high demands in areas such as electromobility and renewable energy applications. These findings significantly contribute to the development of new design guidelines aimed at making future energy storage systems safer and more powerful.