Using Solenoids to Enhance HEV Safety

A hybrid electric vehicle manufacturer needed a solution that would disconnect the lithium-ion battery if the vehicle was involved in an accident.

Customer Problem

HEVs (hybrid electric vehicles) have lithium-ion batteries with voltages as high as 300 to 400 V. When an HEV is involved in an accident, the high-voltage wiring can suffer damage, possibly conducting that voltage through the vehicle’s body. This exposes both passengers and emergency personnel to the risk of electrocution. To mitigate this risk, an OEM needed a solution that would automatically disconnect the lithium-ion battery in the event of a crash.

The TLX Solution

TLX Technologies designed a residual magnetism latching solenoid to actuate the battery-disconnect mechanism. The solenoid’s rest position was de-latched. During an accident, a short voltage pulse energized the solenoid, and the resulting magnetic field drew the plunger to the latched position, disconnecting the battery. The solenoid’s core retained the magnetic field induced by the current pulse and held the armature in the latched position.

View Design Solution

Residual Magnetism Latching Solenoid

Stroke: 2.5 mm
Latching force: 40 N
Response time: < 10 ms
Release current: 1 A
Release response time: 3 ms
Release voltage: 12 Vdc
Durability: > 500K cycles

All TLX components are customized to fit system requirements, meaning technical specifications are unique to each customer and design. Examples given on our website are for illustration purposes only.

Working with TLX

Experienced partner of industry leaders, first-tier suppliers, and OEMs
Direct access to our design and engineering team
Localized production in USA and China
Dependable single-source solution from design to delivery

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Our Process

Step 1 / Initial Review

Our engineering team works directly with you to determine the viability of your program and identify the best solution based on your specifications.

Step 2 / Quote

Quotes include all costs related to your project - tooling, prototype, piece part, production and project specific costs.

Step 3 / Design Review & Prototypes

Our engineering team reviews the design with you and makes any adjustments needed. Prototypes are built according to design specifications for testing.