Minimal Constraint and Precision Placement in Cyclic Testing of High Life-Cycle Products

Abstract

In the electrification of heavy industry, rapid swappable batteries provide an effective means to minimize vehicle downtime and the cost of operation. However, to allow this technology to take hold, further development of electrical contacts that can both pass high amperage and undergo a high cycle life needs to occur. The development of these electrical contacts is a highly experimental process, and thus establishing a method and test equipment to determine the physical and electrical characteristics of these contacts over their lifetime will allow for the accelerated development of these products. This body of work serves as a design guide to establish a physical testing mechanism to assess contact resistance degradation and physical wear over the lifespan of an electric connector. Data will then be collected on initial contact prototypes to characterize their performance. With this data, designs may be iterated and improved upon in pursuit of creating a universal standard for battery swap technology on electric vehicles in heavy industry.