DESC:INTELLIGENT MANUAL SERVICE DISCONNECT FOR TWO-WHEEL ELECTRIC VEHICLES
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202221049848 filed on 31/08/2022, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to a manual service disconnect. Particularly, the present disclosure relates to an intelligent manual service disconnect for opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle. Furthermore, the present disclosure relates to a method of opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle, using an intelligent manual service disconnect. Furthermore, the present disclosure relates to a method of operation of an intelligent manual service disconnect for opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle.
BACKGROUND
Recently, there has been a rapid development in electric vehicles because of their ability to resolve pollution-related problems and serve as a clean mode of transportation. Generally, electric vehicles include a battery pack, power pack, and/or combination of electric cells for storing electricity required for the propulsion of the vehicles. The power pack comprises a battery management system (BMS) that manages the power capacity and functionality of the battery pack. The power pack also comprises a manual service disconnect that allows disconnecting of the high-power circuit of the electric vehicle from the power pack, such as for maintenance of the power pack and/or the electric vehicle. Typically, the manual service disconnect comprises a current fuse creating a fused electrical path for the battery pack coupling with a high voltage interlock (HVIL) that prevents the power pack from being reconnected to the electric vehicle while the manual service disconnect is still in the open position.
The existing manual service disconnects operate at high voltages, thus, there exists a high chance of arcing while disengaging/engaging a disconnect plug of the manual service disconnect. Such arcing may lead to damage to the electrical components connected to the circuit of the electric vehicle. Furthermore, at the service stations, multiple electric vehicles are serviced simultaneously, thus there is a high chance that the disconnect plug of a particular electric vehicle may be mixed up with the disconnect plugs of other vehicles leading to safety hazards as the different electric vehicles may have plugs with different power ratings or configuration.
Therefore, there exists a need for a manual service disconnect that eliminates the chances of arcing while disengagement/engagement and overcomes one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide an intelligent manual service disconnect that eliminates the chances of arcing during disengagement and/or engagement of a disconnect plug of the manual service disconnect.
Another object of the present disclosure is to provide a method of opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle, using an intelligent manual service disconnect.
Yet another object of the present disclosure is to provide a method of operation of an intelligent manual service disconnect for opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle.
In accordance with the first aspect of the present disclosure, there is provided an intelligent manual service disconnect for opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle. The intelligent manual service disconnect comprises a disconnect header, a disconnect plug removably plugged into the disconnect header, a sensing device, a battery disconnect unit, and a wireless identification system. The sensing device is configured within the disconnect header for sensing presence of the disconnect plug in the disconnect header, wherein the sensing device is communicably coupled to a battery management system. The battery disconnect unit is installed in the current flow path between the positive terminal and the negative terminal of the power pack, wherein the battery disconnect unit is communicably coupled to the battery management system. The wireless identification system comprises a unique pair of a tag and a corresponding tag reader.
The present disclosure provides an intelligent manual service disconnect for electrically disengaging the power pack from other electrical components of the electric vehicle. The intelligent manual service disconnect of the present disclosure is advantageous in terms of eliminating chances of arcing while disengaging the disconnect plug from the disconnect header of the manual service disconnect. Furthermore, the intelligent manual service disconnect of the present disclosure is advantageous in terms of providing identification of the disconnect plug resulting in making the particular disconnect plug unique for the particular disconnect header. Furthermore, the intelligent manual service disconnect of the present disclosure is advantageous in terms of eliminating the possibility of plugging a non-compatible disconnect plug into the disconnect header. Moreover, the intelligent manual service disconnect of the present disclosure is advantageous in terms of preventing the electrical components of the electric vehicle from possible damage.
In accordance with the second aspect of the present disclosure, there is provided a method of opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle, using an intelligent manual service disconnect. The method comprises removably plugging a disconnect plug into a disconnect header, configuring a sensing device within the disconnect header for sensing presence of the disconnect plug in the disconnect header and communicably coupling the sensing device to a battery management system, installing a battery disconnect unit in the current flow path between the positive terminal and the negative terminal of the power pack and communicably coupling the battery disconnect unit to the battery management system, and configuring a wireless identification system comprising a unique pair of a tag and a corresponding tag reader in the disconnect plug and the disconnect header respectively.
In accordance with the third aspect of the present disclosure, there is provided a method of operation of an intelligent manual service disconnect for opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle. The method comprises disconnecting a disconnect plug removably plugged into a disconnect header, sending a disconnect signal from a sensing device to a battery management system to cut-off power supply from the power pack, and instructing a battery disconnect unit to open the current flow path between the positive terminal and the negative terminal of the power pack in response to the instruction signal received from the battery management system.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 illustrates a block diagram of an intelligent manual service disconnect for opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle, in accordance with an aspect of the present disclosure.
FIG. 2 illustrates a flow chart of a method of opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle using an intelligent manual service disconnect, in accordance with an embodiment of the present disclosure.
FIG. 3 illustrates a flow chart of a method of operation of an intelligent manual service disconnect for opening a current flow path between a positive terminal and a negative terminal of a power pack of an electric vehicle, in accordance with another aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of an intelligent manual service disconnect and is not intended to represent the only forms that may be developed or utilized. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, or system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “electric vehicle”, “EV”, and “EVs” are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries that are exclusively charged from an external power source, as well as hybrid vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheelers, electric three-wheelers, electric four-wheelers, electric pickup trucks, electric trucks, and so forth.
As used herein, the terms “power source” “battery pack”, “battery”, and “power pack” are used interchangeably and refer to multiple individual battery cells connected to provide a higher combined voltage or capacity than what a single battery can offer. The battery pack is designed to store electrical energy and supply it as needed to various devices or systems. Battery pack, as referred herein may be used for various purposes such as power electric vehicles and other energy storage applications. Furthermore, the battery pack may include additional circuitry, such as a battery management system (BMS), to ensure the safe and efficient charging and discharging of the battery cells. The battery pack comprises a plurality of cell arrays which in turn comprises a plurality of battery cells.
As used herein, the terms “manual service disconnect”, “service disconnect” and “MSD” are used interchangeably and refer to a safety device used in electric vehicles to disconnect the high-voltage power pack from the rest of the electrical systems of the electric vehicle. It is to be understood that the manual service disconnect is necessary for servicing the power pack or other high-voltage components, as it prevents accidental contact of the service personnel with live voltage. Typically, the manual service disconnect is located near the power pack and is accessible without the need of any tool. Furthermore, the manual service disconnect is typically equipped with a high-voltage interlock loop, which prevents the battery pack from being reconnected while the MSD is still in the open position. Beneficially, the manual service disconnect prevents electric shock and fire during the service operation of the power pack or the electric vehicle.
As used herein, the terms “battery management system” and “BMS” are used interchangeably and refer to a component of the electric vehicle that monitors, controls, and optimizes the performance and safety of the power pack. The battery management system performs crucial functions including state of charge estimation and monitoring, state of health monitoring, thermal management, cell balancing, over-voltage and under-voltage protection, safety management, communication and data reporting, and efficiency optimization. The battery management system comprises a microcontroller to perform the processing tasks.
As used herein, the term “disconnect header” refers to a component of the manual service disconnect that receives a disconnect plug to execute the service disconnect operation. Furthermore, the disconnect header may house other components of the manual service disconnect. It is to be understood that the disconnect header may be located in close proximity to the power pack. Beneficially, such location of the disconnect header would reduce the requirement of wiring harness in the electric vehicle.
As used herein, the term “disconnect plug” refers to a removable plug that is removed from the disconnect header to open the manual service disconnect. It is to be understood that the disconnect plug is plugged into the disconnect header to close the manual service disconnect.
As used herein, the term “sensing device” refers to a component of the manual service disconnect that is capable of determining the presence of the disconnect plug in the disconnect header. The sensing device may comprise at least one of: a current sensor, a voltage sensor, a resistance sensor, or a combination thereof.
As used herein, the term “battery disconnect unit” refers to a component of the manual service disconnect that is configured to physically open the current flow path (circuit) to disconnect the power pack from the current flow path. The battery disconnect unit may comprise at least one of: a metal oxide semiconductor field effect transistor, a circuit breaker, a contactor, or a combination thereof.
As used herein, the term “wireless identification system” refers to a system that identifies or tracks components or objects. The wireless identification system may comprise a unique pair of identity tags and tag readers. The wireless identification system may be radio frequency identification. Alternatively, the wireless identification system may comprise any other suitable technology known to the person skilled in the art.
As used herein, the term ‘communicably coupled’ refers to a communicational connection between the various components of the system. The communicational connection between the various components of the system enables the exchange of data between two or more components of the system.
Figure 1, in accordance with an embodiment, describes an intelligent manual service disconnect 100 for opening a current flow path between a positive terminal and a negative terminal of a power pack 102 of an electric vehicle. The intelligent manual service disconnect 100 comprises a disconnect header 104, a disconnect plug 106, a sensing device 108, a battery disconnect unit 112, and a wireless identification system 114. The disconnect plug 106 is removably plugged into the disconnect header 104. The sensing device 108 is configured within the disconnect header 104 for sensing presence of the disconnect plug 106 in the disconnect header 104, wherein the sensing device 108 is communicably coupled to a battery management system 110. The battery disconnect unit 112 is installed in the current flow path between the positive terminal and the negative terminal of the power pack 102, wherein the battery disconnect unit 112 is communicably coupled to the battery management system 110. The wireless identification system 114 comprises a unique pair of a tag 114a and a corresponding tag reader 114b.
The intelligent manual service disconnect 100 electrically disengages the power pack 102 from other electrical components of the electric vehicle. The intelligent manual service disconnect 100 of the present disclosure is advantageous in terms of eliminating chances of arcing while disengaging the disconnect plug 106 from the disconnect header 104 of the intelligent manual service disconnect 100. Furthermore, the intelligent manual service disconnect 100 of the present disclosure is advantageous in terms of providing identification of the disconnect plug 106 resulting in making the particular disconnect plug 104 unique for the particular disconnect header 106. Furthermore, the intelligent manual service disconnect 100 of the present disclosure is advantageous in terms of eliminating the possibility of plugging a non-compatible disconnect plug into the disconnect header 104. Moreover, the intelligent manual service disconnect 100 of the present disclosure is advantageous in terms of preventing the electrical components of the electric vehicle from possible damage.
In an embodiment, the disconnect header 104 and the disconnect plug 106 are configured at a current and a voltage significantly lower than a current and a voltage in the current flow path between the positive terminal and the negative terminal of the power pack 102. It is to be understood that the pair of the disconnect header 104 and the disconnect plug 106 is a low voltage low current system that may act as a signal generator for the actual disconnection of the power pack 102. Beneficially, the lower voltage and lower current of the disconnect header 104 and the disconnect plug 106 eliminate the possibility of arcing during the disengagement of the disconnect plug 106 from the disconnect header 104 or during the engagement of the disconnect plug 106 to the disconnect header 104.
In an embodiment, the sensing device 108 sends a disconnect signal to the battery management system 110 to cut-off the power supply from the power pack 102 when the disconnect plug 106 is unplugged from the disconnect header 104. It is to be understood that the sensing device 108 detects (senses) whether the disconnect plug 106 is plugged into the disconnect header 104. Furthermore, the sensing device 108 monitors the presence of the disconnect plug 106 in the disconnect header 104. When the disconnect plug 106 is unplugged from the disconnect header 104 the sensing device 108 senses such event and generates the disconnect signal for sending to the battery management system 110 to cut-off power supply from the power pack 102. Beneficially, such sensing of the disconnection of the disconnect plug 106 from the disconnect header 104 enables the system to intelligently cut-off power supply from the power pack 102 without the chances of arcing in the current flow path between the positive terminal and the negative terminal of the power pack 102 resulting into enhanced safety of the electrical components of the electric vehicle.
In an embodiment, the battery management system 110 instructs the battery disconnect unit 112 to cut-off power supply from the power pack 102, in response to the disconnect signal received from the sensing device 108. It is to be understood that when the battery management system 110 receives the disconnect signal from the sensing device 108, the battery management system 110 generates the instruction for the battery disconnect unit 112 to cut-off power supply from the power pack 102. Beneficially, the battery disconnect unit 112 disconnects the power pack 102 from the current flow path resulting in cutting-off the power supply from the power pack 102. Beneficially, the disconnection of the power pack 102 from the current flow path eliminates the possibility of arcing in the current flow path of the electric vehicle preventing any potential damage to the electrical components of the electric vehicle.
In an embodiment, the battery disconnect unit 112 comprises at least one of: MOSFETs, circuit breakers, contactors, or a combination thereof. Beneficially, the battery disconnect unit 112 is designed to prevent arcing while functioning to connect or disconnect the power pack 102.
In an embodiment, the battery disconnect unit 112 opens the current flow path between the positive terminal and the negative terminal of the power pack 102, in response to the instruction received from the battery management system 110. It is to be understood that the current flow path between the positive terminal and the negative terminal of the power pack 102 is opened by disconnecting the power pack 102 from the current flow path. Beneficially, the opening of the current flow path ensures safety during the service operation of the electric vehicle and/or the power pack 102.
In an embodiment, the unique tag 114a of the wireless identification system 114 is installed in the disconnect plug 106 and the corresponding tag reader 114b is installed in the disconnect header 104 to provide a unique identification to the disconnect plug 106 and the disconnect header 104. Beneficially, such unique identification of the disconnect plug 106 and the disconnect header 104 prevents plugging of non-compatible disconnect plug into the disconnect header 104.
In an embodiment, the sensing device 108 restore the current flow path between the positive terminal and the negative terminal of the power pack 102 after the identity of the disconnect plug 106 plugged into the disconnect header 104 is validated by pairing of the unique tag 114a and the corresponding tag reader 114b. It is to be understood that when disconnect plug is re-plugged into the disconnect header 104, the sensing device 108 validates whether the re-plugged disconnect plug is the disconnect plug 106 specifically meant for the disconnect header 104 by pairing of the unique tag 114a and the corresponding tag reader 114b. Once, it is established that the re-plugged disconnect plug is the disconnect plug 106, the sensing device 108 generates a connect signal and sends the connect signal to the battery management system 110. The battery management system 110 instructs the battery disconnect unit 112 to restore the power supply from the power pack 102. The battery disconnect unit 112 closes the current flow path between the positive terminal and the negative terminal of the power pack 102 to restore the power supply from the power pack 102.
In an exemplary embodiment, during the normal operation of the electric vehicle, the disconnect plug 106 is plugged the disconnect header 104. Once a user wants to execute a service disconnect for opening the current flow path, the user would remove the disconnect plug 106 from the disconnect header 104. The sensing device 108 senses that the disconnect plug 106 is disconnected from the disconnect header 104. The sensing device 108 generates and sends the disconnect signal to the battery management system 110. The battery management system 110 instructs the battery disconnect unit 112 to cut-off the power supply from the power pack 102 by disconnecting the power pack 102 from the current flow path. Such disconnection of the power pack 102 from the current flow path opens the current flow path between the positive terminal and the negative terminal of the power pack 102 of the electric vehicle.
Figure 2, describes a method 200 of opening a current flow path between a positive terminal and a negative terminal of a power pack 102 of an electric vehicle, using an intelligent manual service disconnect 100. The method 200 starts at step 202 and completes at step 208. At step 202, the method 200 comprises removably plugging, a disconnect plug 106, into a disconnect header 104. At step 204, the method 200 comprises configuring, a sensing device 108, within the disconnect header 104 for sensing presence of the disconnect plug 106 in the disconnect header 104, and communicably coupling the sensing device 108 to a battery management system 110. At step 206, the method 200 comprises installing, a battery disconnect unit 112, in the current flow path between the positive terminal and the negative terminal of the power pack 102, and communicably coupling the battery disconnect unit 112 to the battery management system 110. At step 208, the method 200 comprises configuring, a wireless identification system 114 comprising a unique pair of a tag 114a and a corresponding tag reader 114b in the disconnect plug 106 and the disconnect header 104 respectively.
In an embodiment, the method 200 comprises configuring the disconnect header 104 and the disconnect plug 106 at a current and a voltage significantly lower than a current and a voltage in the current flow path between the positive terminal and the negative terminal of the power pack 102. Beneficially, the lower voltage and lower current of the disconnect header 104 and the disconnect plug 106 eliminate the possibility of arcing during the disengagement of the disconnect plug 106 from the disconnect header 104 or during the engagement of the disconnect plug 106 to the disconnect header 104.
In an embodiment, the method 200 comprises sending, from the sensing device 108, a disconnect signal to the battery management system 110 to cut-off power supply from the power pack 102 when the disconnect plug 106 is unplugged from the disconnect header 104. Beneficially, the disconnection of the disconnect plug 106 from the disconnect header 104 is sensed to send the disconnect signal. Beneficially, sending such disconnect signal enables intelligent cut-off of the power supply from the power pack 102 without the chances of arcing in the current flow path between the positive terminal and the negative terminal of the power pack 102 resulting in enhanced safety of the electrical components of the electric vehicle.
In an embodiment, the method 200 comprises instructing, by the battery management system 110, the battery disconnect unit 112 to cut-off power supply from the power pack 102, in response to the disconnect signal received from the sensing device 108. Beneficially, the disconnection of the power pack 102 from the current flow path results in cutting-off the power supply from the power pack 102. Beneficially, the disconnection of the power pack 102 from the current flow path eliminates the possibility of arcing in the current flow path of the electric vehicle preventing any potential damage to the electrical components of the electric vehicle. Beneficially, the opening of the current flow path ensures safety during the service operation of the electric vehicle and/or the power pack 102.
In an embodiment, the method 200 comprises restoring the current flow path between the positive terminal and the negative terminal of the power pack 102 after the identity of the disconnect plug 106 plugged into the disconnect header 104 is validated by pairing of the unique tag 114a and the corresponding tag reader 114b. It is to be understood that when disconnect plug is re-plugged into the disconnect header 104, the method 200 comprises validating whether the re-plugged disconnect plug is the disconnect plug 106 specifically meant for the disconnect header 104 by pairing of the unique tag 114a and the corresponding tag reader 114b. Once, it is established that the re-plugged disconnect plug is the disconnect plug 106, the method 200 comprises generating a connect signal and sending the connect signal to the battery management system 110. The method 200 comprises instructing the battery disconnect unit 112 to restore the power supply from the power pack 102. The method 200 comprises closing the current flow path between the positive terminal and the negative terminal of the power pack 102 to restore the power supply from the power pack 102.
Figure 3, describes a method 300 of operation of an intelligent manual service disconnect 100 for opening a current flow path between a positive terminal and a negative terminal of a power pack 102 of an electric vehicle. The method 300 starts at step 302 and completes at step 306. At step 302, the method 300 comprises disconnecting, a disconnect plug 106, removably plugged into a disconnect header 104. At step 304, the method 300 comprises sending, a disconnect signal from a sensing device 108 to a battery management system 110 to cut-off power supply from the power pack 102. At step 306, the method 300 comprises instructing, a battery disconnect unit 112 to open the current flow path between the positive terminal and the negative terminal of the power pack 102, in response to the instruction signal received from the battery management system 110.
It would be appreciated that all the explanations and embodiments of the intelligent manual service disconnect 100 and method 200 also apply mutatis-mutandis to the method 300.
In another aspect of the present disclosure, there is disclosed a computer program product comprising a non-transitory computer-readable storage medium having computer-readable instructions stored thereon, the computer-readable instructions being executable by a computerized device comprising processing hardware to execute method 200 and method 300.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combinations of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, and “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

,CLAIMS:WE CLAIM:
1. An intelligent manual service disconnect (100) for opening a current flow path between a positive terminal and a negative terminal of a power pack (102) of an electric vehicle, wherein the intelligent manual service disconnect (100) comprises:
- a disconnect header (104);
- a disconnect plug (106) removably plugged into the disconnect header (104);
- a sensing device (108) configured within the disconnect header (104) for sensing presence of the disconnect plug (106) in the disconnect header (104), wherein the sensing device (108) is communicably coupled to a battery management system (110);
- a battery disconnect unit (112) installed in the current flow path between the positive terminal and the negative terminal of the power pack (102), wherein the battery disconnect unit (112) is communicably coupled to the battery management system (110); and
- a wireless identification system (114) comprising a unique pair of a tag (114a) and a corresponding tag reader (114b).
2. The intelligent manual service disconnect (100) as claimed in claim 1, wherein the disconnect header (104) and the disconnect plug (106) are configured at a current and a voltage significantly lower than a current and a voltage in the current flow path between the positive terminal and the negative terminal of the power pack (102).
3. The intelligent manual service disconnect (100) as claimed in any of the claims 1 and 2, wherein the sensing device (108) sends a disconnect signal to the battery management system (110) to cut-off power supply from the power pack (102) when the disconnect plug (106) is unplugged from the disconnect header (104).
4. The intelligent manual service disconnect (100) as claimed in any of the claims 1 to 3, wherein the battery management system (110) instructs the battery disconnect unit (112) to cut-off power supply from the power pack (102), in response to the disconnect signal received from the sensing device (108).
5. The intelligent manual service disconnect (100) as claimed in any of the claims 1 to 4, wherein the battery disconnect unit (112) opens the current flow path between the positive terminal and the negative terminal of the power pack (102), in response to the instruction received from the battery management system (110).
6. The intelligent manual service disconnect (100) as claimed in claim 1, wherein the unique tag (114a) of the wireless identification system (114) is installed in the disconnect plug (106) and the corresponding tag reader (114b) is installed in the disconnect header (104) to provide a unique identification to the disconnect plug (106) and the disconnect header (104).
7. The intelligent manual service disconnect (100) as claimed in claim 6, wherein the sensing device (108) restore the current flow path between the positive terminal and the negative terminal of the power pack (102) after the identity of the disconnect plug (106) plugged into the disconnect header (104) is validated by pairing of the unique tag (114a) and the corresponding tag reader (114b).
8. A method (200) of opening a current flow path between a positive terminal and a negative terminal of a power pack (102) of an electric vehicle, using an intelligent manual service disconnect (100), wherein the method (200) comprises:
- removably plugging, a disconnect plug (106), into a disconnect header (104);
- configuring, a sensing device (108), within the disconnect header (104) for sensing presence of the disconnect plug (106) in the disconnect header (104), and communicably coupling the sensing device (108) to a battery management system (110);
- installing, a battery disconnect unit (112), in the current flow path between the positive terminal and the negative terminal of the power pack (102), and communicably coupling the battery disconnect unit (112) to the battery management system (110); and
- configuring, a wireless identification system (114) comprising a unique pair of a tag (114a) and a corresponding tag reader (114b) in the disconnect plug (106) and the disconnect header (104) respectively.
9. The method (200) as claimed in claim 8, wherein the method (200) comprises configuring the disconnect header (104) and the disconnect plug (106) at a current and a voltage significantly lower than a current and a voltage in the current flow path between the positive terminal and the negative terminal of the power pack (102).
10. The method (200) as claimed in claim 8, wherein the method (200) comprises sending, from the sensing device (108), a disconnect signal to the battery management system (110) to cut-off power supply from the power pack (102) when the disconnect plug (106) is unplugged from the disconnect header (104).
11. The method (200) as claimed in any of the claims 8 to 10, wherein the method (200) comprises instructing, by the battery management system (110), the battery disconnect unit (112) to cut-off power supply from the power pack (102), in response to the disconnect signal received from the sensing device (108).
12. The method (200) as claimed in any of the claims 8 to 11, wherein the method (200) comprises opening, by the battery disconnect unit (112), the current flow path between the positive terminal and the negative terminal of the power pack (102), in response to the instruction received from the battery management system (110).
13. The method (200) as claimed in claim 8, wherein the method (200) comprises restoring the current flow path between the positive terminal and the negative terminal of the power pack (102) after the identity of the disconnect plug (106) plugged into the disconnect header (104) is validated by pairing of the unique tag (114a) and the corresponding tag reader (114b).
14. A method (300) of operation of an intelligent manual service disconnect (100) for opening a current flow path between a positive terminal and a negative terminal of a power pack (102) of an electric vehicle, wherein the method (300) comprises:
- disconnecting, a disconnect plug (106), removably plugged into a disconnect header (104);
- sending, a disconnect signal from a sensing device (108) to a battery management system (110) to cut-off power supply from the power pack (102); and
- instructing, a battery disconnect unit (112) to open the current flow path between the positive terminal and the negative terminal of the power pack (102), in response to the instruction signal received from the battery management system (110).