Fuse availability detection and replaceability in power electronics systems

Abstract

A power electronic device and / or system includes a power electronic circuit, a terminal for electrical coupling to the power electronic circuit, a sealed housing, a fuse disposed outside the sealed housing, and a comparator disposed within the sealed housing. A power electronic circuit is disposed within the sealed housing and electrical access is achieved through terminals extending out of the sealed housing. The fuse is electrically coupled to the power electronic circuit and the terminal. The comparator is coupled to receive a first current or voltage value from a first test point located on a first electrical path through the fuse between the terminal and the power electronic circuit and a second current or voltage value from a second test point located on a second electrical path through the fuse between the terminal and the power electronic circuit. A second test point is located on a second electrical path through the fuse between the terminal and the power electronic circuit.

Description

Cross-reference to applications related to fuse availability testing and replaceability in power electronic systems

[0001] This invention claims the benefit of Indian Provisional Application No. 202311059267, filed September 4, 2023; Indian Provisional Application No. 202411004709, filed January 23, 2024; and Indian Provisional Application No. 202411004710, filed January 23, 2024, the entire contents of which (including any drawings, tables and figures) are incorporated herein by reference. Background Technology

[0002] Power electronic equipment and systems (e.g., inverters, converters, battery and electric heater equipment and systems) typically need to be sealed to prevent damage, and maintaining this sealing is usually part of the system's warranty. Fuses in these systems frequently blow and / or become unusable, requiring replacement. However, replacing a fuse necessitates opening the sealed portions of these systems, potentially causing damage and voiding the warranty. Therefore, a solution is needed that allows for fuse replacement without opening the sealed portions of these systems. Similarly, the ability to detect when these fuses fail is needed so that they can be replaced. Summary of the Invention

[0003] A power electronic system (e.g., an electric heater, converter, inverter, and / or battery) is provided, which has a replaceable fuse located outside a sealed portion of the electrical system. Advantageously, this electrical system provides the ability to easily and conveniently replace the fuse without damaging the seal of the power electronic system housing. Furthermore, comparators electrically coupled to each side of the replaceable fuse provide the ability to detect the status (e.g., availability) of the replaceable fuse.

[0004] A power electronic device and / or system includes a power electronic circuit, terminals for electrical coupling to the power electronic circuit, a sealed housing, a fuse disposed outside the sealed housing, and a comparator disposed within the sealed housing. The power electronic circuit is disposed within the sealed housing and electrically connected via terminals extending out of the sealed housing. The fuse is electrically coupled to the power electronic circuit and the terminals. The comparator is coupled to receive a first current or voltage value from a first test point and a second current or voltage value from a second test point, the first test point being located on a first electrical path passing through the fuse between the terminals and the power electronic circuit, and the second test point being located on a second electrical path passing through the fuse between the terminals and the power electronic circuit.

[0005] A method for replacing a fuse in a power electronic system includes: disconnecting an electrical connection from a terminal; removing at least a portion of an overmolded feature or terminal; replacing the fuse; re-inserting said at least a portion of the overmolded feature or terminal; and reattaching the electrical connection to the terminal. The fuse is located outside a sealed housing of the power electronic system.

[0006] This summary is provided to introduce some concepts in a simplified form, which will be further described in the detailed embodiments below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter. Attached Figure Description

[0007] Figure 1 shows a schematic diagram of a mobile application with a DC / DC converter with a fuse.

[0008] Figures 2A and 2B show the top cover of a power electronic system with a fully enclosed connector.

[0009] Figures 3A and 3B show terminal assemblies designed for use as fully enclosed connectors for receiving power electronic systems.

[0010] Figure 3C shows a fully enclosed connector for power electronic systems.

[0011] Figures 4A to 4G show cross-sectional views of an embodiment of a terminal assembly with a replaceable fuse located outside the power electronics system receiving a fully enclosed connector.

[0012] Figures 5A to 5E show cross-sectional views of an embodiment of a terminal assembly with a replaceable fuse located outside the power electronics system receiving a ring connector.

[0013] Figures 6A and 6B show the top cover of a power electronic system with an RD8 connector.

[0014] Figures 7A to 7G show portions of terminal assemblies configured to supply power to a power electronic system using RD8 connectors.

[0015] Figures 8A and 8B show cross-sectional views of an embodiment of a terminal assembly with a replaceable fuse located outside the power electronics system receiving the RD8 connector.

[0016] Figure 9 shows a process flow diagram describing the method for replacing fuses in a power electronic system.

[0017] Figures 10A to 10C show comparators for testing the voltage or current on either side of a fuse in a power electronic device and / or system.

[0018] Figure 11 shows a cross-sectional view of an embodiment of a terminal assembly and a replaceable fuse located outside the power electronics system.

[0019] Figure 12 shows a cross-sectional view of an embodiment of a terminal assembly and a replaceable fuse located outside the power electronics system receiving a fully enclosed connector.

[0020] Figure 13 shows a cross-sectional view of an embodiment of current flowing through a terminal assembly and a replaceable fuse located outside the power electronics system receiving the ring connector.

[0021] Figure 14 shows a cross-sectional view of an embodiment of current flowing through a terminal assembly and a replaceable fuse located outside the power electronics system receiving the RD8 connector. Detailed Implementation

[0022] A power electronic system (e.g., an electric heater, converter, inverter, and / or battery) is provided, which has a replaceable fuse located outside a sealed portion of the electrical system. Advantageously, this electrical system provides the ability to easily and conveniently replace the fuse without damaging the seal of the power electronic system's housing. Furthermore, electrically coupled comparators on each side of the replaceable fuse provide the ability to detect the state (e.g., operability) of the replaceable fuse.

[0023] While some examples of 48V to 12V DC / DC converters are described herein, it should be understood that other types of converters, inverters, electric heaters, and battery systems may include some or all of the features described herein. Furthermore, some or all of the features described herein may be modified to be implemented in specific types of converters, inverters, electric heaters, and / or battery systems, and shall still remain within the scope of this disclosure.

[0024] Figure 1 illustrates a schematic diagram of a mobile application with a DC / DC converter featuring a fuse. Referring to Figure 1, the schematic diagram 100 of the mobile application includes a starter motor 102, an internal combustion engine 104, a transmission 106, and an electric motor / generator (M / G) 108 that supplies energy to a 48V battery 110 and / or directly to a DC / DC converter 112 (e.g., 48V to 12V). The DC / DC converter 112 has a first fuse 114 located on the power input side (e.g., the 48V side) and a second fuse 116 located on the power output side (e.g., the 12V side). Schematic diagram 100 also includes a 12V battery 118 powered via the power output side of the DC / DC converter 112. The 48V battery 110 and / or the M / G 108 power a 48V load 120, and the 12V battery 118 and / or the power output side of the DC / DC converter 112 power a 12V load 122. It can be seen that both the first fuse 114 and / or the second fuse 116 can be points of failure, preventing the 12V load 122 from being powered. For example, once the 12V battery is depleted, it must rely on power from the DC / DC converter 112 to be charged. The first fuse 114 and the second fuse 116 are replaceable fuses.

[0025] Figures 2A and 2B illustrate the top cover of a power electronic system with a fully enclosed connector. Figure 2A includes a line from X to X', which represents a cut-through line through the top cover 200 of the power electronic device and / or system (e.g., the electric heater, converter, inverter, and / or battery system shown in Figures 4B to 4G). Referring to Figures 2A and 2B, the top cover 200 of the DC / DC converter includes one or more terminal assemblies 202, 204. In some cases, there is one power input terminal assembly 202 and one power output terminal assembly 204. For example, the power input terminal assembly 202 includes 48V power entering the DC / DC converter, and the power output terminal assembly 204 includes 12V power leaving the DC / DC converter (e.g., as shown in Figure 1). In some cases, a ground terminal assembly 206 is included. While power input terminal assembly 202 and power output terminal assembly 204 are shown as fully enclosed connectors, such as Aptiv® connectors, in some cases, power input terminal assembly 202, power output terminal assembly 204 and / or ground terminal assembly 206 are configured to receive ring terminal connectors, post connectors, RD8 connectors, harness-side RD8 connectors and / or any other type of connector for coupling wiring to power input terminal assembly 202 and power output terminal assembly 204.

[0026] Figures 3A and 3B illustrate a terminal assembly designed for use with a fully enclosed connector in a power electronic system. Referring to Figures 3A and 3B, the terminal assembly 300 includes terminals 302 and an overmold feature 304 located within a post 306 of an electric heater, converter, inverter, and / or battery. In some cases, the overmold feature 304 is made of a non-conductive material.

[0027] Figure 3C illustrates a fully enclosed connector for power electronic systems. Referring to Figure 3C, the fully enclosed connector 310 includes: an outer housing 312; a snap-on cover 314 connected to the outer housing 312 via a hinge 316 (e.g., for sealing the electrical connection to the terminal assembly 300); a wire 318; a cable connector 320; and a seal 322 that engages between the wire 318 and the cable connector 320 to provide a waterproof seal where the wire 318 enters the outer housing 312. The fully enclosed connector 310 prevents corrosion, abrasion, tearing, and other deteriorating effects on the electrical connection of the terminal assembly 300 that occur during normal use of the power electronic equipment and / or system.

[0028] Figures 4A to 4G show cross-sectional views of an embodiment of a terminal assembly with a replaceable fuse located outside a power electronic system receiving a fully enclosed connector. Referring to Figures 4A to 4G, a terminal assembly 400 of a power electronic device and / or system includes a power electronic circuit 402, a terminal 404 for electrical coupling to the power electronic circuit 402, a sealed housing 406 (or a sealed portion), a fuse 408 disposed outside the sealed housing 406, a post 410, and, in some cases (such as those shown in Figures 4D and 4E), an overmolding feature positioned around at least a portion of the terminal 404 and within the post 410. The fuse is electrically coupled to the power electronic circuit 402 and the terminal 404. The fuse 408 may be located below the overmolding feature 412 and / or a portion of the terminal 404, and positioned around at least a portion of the terminal 404. The power electronic circuit 402 is disposed within the sealed housing 406 and is electrically connected via terminals extending out of the sealed housing 406. The top cover (as shown in Figures 2A and 2B) is separate from the sealing housing 406.

[0029] Terminal 404 includes an external terminal 414 for attachment to a fully enclosed connector 416 and an internal terminal 418 coupled to the external terminal 414 for attachment to a power electronic circuit 402. In some cases, the internal terminal 418 provides compressive force to the power electronic circuit 402 when attached to the external terminal 414. In some cases, the internal terminal 418 is attached to the external terminal 414 via a press fit. In some cases, the internal terminal 418 is attached to the external terminal 414 via a nut and bolt configuration. In some cases, the internal terminal 418 includes a longitudinal shaft 420 and an enlarged head 422 attached to the end of the longitudinal shaft 420. In some cases, as shown in FIG. 4B, a washer / bolt or only a bolt is used instead of the enlarged head 422. In some cases, an overmolded feature 412 is positioned around the external terminal 414. In some cases, a fuse 408 is located below the external terminal 414.

[0030] In some cases, as shown in Figure 4D, the terminal assembly 400 further includes a spring force element 424. In some cases, the fuse 408 is electrically coupled to the terminal 404 via the spring force element 424. In some cases, the terminal assembly 400 also includes a conductive element 426 that electrically couples the fuse 408 to the power electronic circuit 402.

[0031] In some cases, fuse 408 is inserted and / or snapped into place by mating with at least a portion of terminal 404. In some cases, fuse 408 is a marine-grade battery fuse. In some cases, terminal assembly 400 also includes an O-ring 428 to provide sufficient pressure during normal use of the power electronics equipment and / or system to hold overmolded feature 412 and / or fully enclosed connector 416 and / or post 410 in place. O-ring 428 may be located between post 410 and connector block 430. In some cases, as shown in FIG4E, overmolded feature 412 includes snap-fit ​​features to further prevent corrosion, abrasion, tearing, and other deteriorating effects on terminal assembly 400 during normal use of power electronics equipment and / or system.

[0032] In some cases, the power electronic circuit 402 is a printed circuit board (PCB). Comparators (such as those described with reference to Figures 10A to 10C) are also arranged within a sealed housing 406. In some cases, the comparators are formed as part of the power electronic circuit 402.

[0033] Power input and power output can be supplied / implemented via one or more fully enclosed connectors 416 electrically coupled to terminal 404 (e.g., one fully enclosed connector 416 for each terminal assembly 400).

[0034] Figures 5A to 5E show cross-sectional views of embodiments of terminal assemblies with replaceable fuses located outside the power electronic system receiving a ring connector. Although Figures 5A to 5E show a single terminal assembly, power electronic devices and / or systems using ring connectors may include one or more terminal assemblies. In some cases, there is one power input terminal assembly and one power output terminal assembly. In some cases, a grounding terminal is also included.

[0035] Referring to Figures 5A to 5E, the terminal assembly 500 includes: a terminal 502 (e.g., a bolt); an overmolded feature 504 positioned around at least a portion of the terminal 502 and located within a post 506 of the terminal assembly 500; and a fuse 508 located below the overmolded feature 504 around at least a portion of the terminal 502. In some cases, the terminal 502 is a bolt. In some cases, the fuse 508 can be inserted and / or engaged by engaging around at least a portion of the terminal 502. In some cases, the fuse 508 is a marine-grade battery fuse. In some cases, an O-ring 510 is included in the terminal assembly 500 to provide sufficient pressure during normal use of the power electronics equipment and / or system to hold the overmolded feature 504 in place. The O-ring 510 may be located between the post 506 and the connector block 512 of the terminal assembly 500.

[0036] The terminal assembly 500 also includes a power electronic circuit 514 electrically coupled to it. In some cases, the power electronic circuit 514 is a printed circuit board (PCB). The top cover 200 forms at least a portion of the hermetically sealed housing 516 of the DC / DC converter. Terminals 502 of the terminal assembly 500 are electrically coupled to the power electronic circuit 514, and the power electronic circuit 514 is arranged within the hermetically sealed housing 516 of the power electronic equipment and / or system. The terminal assembly 500 provides electrical access via terminals 502 extending out of the hermetically sealed housing 516. A fuse 508 is arranged outside the hermetically sealed housing 516 and is electrically coupled to the power electronic circuit 514 and terminals 502. The top cover (e.g., as shown in Figures 2A and 2B) is separate from the hermetically sealed housing 516.

[0037] Comparators (such as those described with reference to Figures 10A to 10C) are also arranged within the sealed housing 516. In some cases, the comparators are formed as part of the power electronic circuit 514.

[0038] Power input and power output can be supplied / implemented via one or more terminal wire connection mechanisms 518 electrically coupled to terminal 502 (e.g., one terminal wire connection mechanism per terminal assembly 500). One or more terminal wire connection mechanisms 518 are secured to terminal 502 via terminal locking mechanisms 520 (e.g., thereby ensuring electrical coupling). For example, terminal 502 is a bolt, and terminal locking mechanism 520 is a nut. In other cases, terminal locking mechanism 520 can be any other mechanism capable of securing one or more terminal wire connection mechanisms 518 to terminal 502. Although terminal assembly 500 is shown as a ring terminal connector, in some cases, terminal assembly 500 is configured to receive fully enclosed connectors, post connectors, RD8 connectors, harness-side RD8 connectors, and / or any other type of connector for coupling wiring to terminal assembly 500.

[0039] Figures 6A and 6B illustrate the top cover of a power electronic system with RD8 connectors. Referring to Figures 6A and 6B, the top cover 600 of the power electronic device and / or system includes one or more terminal assemblies 602, 604. In some cases, there is a power input terminal assembly 602 and a power output terminal assembly 604. For example, the power input terminal assembly 602 includes 48V power entering the DC / DC converter, and the power output terminal assembly 604 includes 12V power leaving the DC / DC converter. In some cases, a ground terminal assembly 606 is included. Although the power input terminal assembly 602 and the power output terminal assembly 604 are shown as RD8 connectors, in some cases, the power input terminal assembly 602, the power output terminal assembly 604, and / or the ground terminal assembly 606 are configured to receive ring terminal connectors, post connectors, harness-side RD8 connectors, and / or fully enclosed connectors (e.g., Aptiv® connectors).

[0040] Figures 7A to 7G illustrate portions of a terminal assembly configured to supply power to a power electronic system using an RD8 connector. Referring to Figures 7A to 7G, the terminal assembly includes an overmolded feature 702, a terminal 704, an RD8 connector 706, and a post 708. Specifically, the overmolded feature 702 is located within the post 708 and positioned around the terminal 704. The RD8 connector 706 mates with and is fitted into the terminal 704 on the post 708. The RD8 connector 706 prevents corrosion, abrasion, tearing, and other deteriorating effects from occurring on the terminal assembly during normal use of the power electronic equipment and / or system.

[0041] Figures 8A and 8B show cross-sectional views of an embodiment of a terminal assembly with a replaceable fuse located outside the power electronic system receiving an RD8 connector. Referring to Figures 8A and 8B, the terminal assembly 800 of the power electronic device and / or system includes a power electronic circuit 802, a terminal 804 for electrical coupling to the power electronic circuit 802, a sealed housing 806, a fuse 808 disposed outside the sealed housing 806, a post 810, and an overmolding feature 812 positioned around at least a portion of the terminal 804 and within the post 810. The fuse is electrically coupled to the power electronic circuit 802 and the terminal 804. The fuse 808 may be located below the overmolding feature 812 and / or a portion of the terminal 804, and positioned around at least a portion of the terminal 804. The power electronic circuit 802 is disposed within the sealed housing 806 and is electrically connected via the terminal 804 extending out of the sealed housing 806. The top cover (as shown in Figures 2A, 2B, 6A and 6B) is separate from the sealing housing 806.

[0042] Terminal 804 includes an external terminal 814 for attachment to an RD8 connector 816 and an internal terminal 818 coupled to the external terminal 814 for attachment to a power electronic circuit 802. In some cases, the internal terminal 818 provides a compressive force to the power electronic circuit 802 when attached to the external terminal 814. In some cases, the internal terminal 818 is attached to the external terminal 814 via a press fit. In some cases, the internal terminal 818 is attached to the external terminal 814 via a nut and bolt configuration. In some cases, the internal terminal 818 includes a longitudinal shaft 820 attached to a bolt 822, which secures the bolt to the power electronic circuit 802. In some cases, an overmolded feature 812 is positioned around the external terminal 814. In some cases, a fuse 808 is located below the external terminal 814. In some cases, the terminal assembly 800 also includes a conductive element 826 electrically coupling the fuse 808 to the power electronic circuit 802.

[0043] In some cases, fuse 808 is inserted and / or snapped into place by engaging with at least a portion of terminal 804. In some cases, fuse 808 is a marine-grade battery fuse. In some cases, terminal assembly 800 also includes an O-ring 828 to provide sufficient pressure during normal use of the power electronic equipment while holding overmolded feature 812 and / or RD8 connector 816 and / or post 810 in place. O-ring 828 may be located between post 810 and connector block 830. In some cases, overmolded feature 812 includes snap-fit ​​features to further prevent corrosion, abrasion, tearing, and other deteriorating effects on terminal assembly 800 during normal use of the power electronic equipment and / or system. Comparators (such as those described with reference to Figures 10A to 10C) are also arranged within hermetically sealed housing 806. In some cases, the comparator is formed as part of power electronic circuitry 802.

[0044] Figure 9 shows a process flow diagram illustrating a method for replacing a fuse in a power electronic system. Referring to Figure 9, the method 900 for replacing a fuse in a power electronic system includes: disconnecting (902) an electrical connection from a terminal; removing (904) at least a portion of an overmolded feature or terminal; replacing (906) the fuse; re-inserting (908) at least a portion of the overmolded feature or terminal; and reattaching (910) the electrical connection to the terminal. The fuse is located outside the sealed housing of the power electronic device and / or system.

[0045] In some cases where a fully enclosed connector is used, disconnecting (902) the electrical connection includes removing the fully enclosed connector from the external terminal, and removing (904) at least a portion of the overmolded feature or terminal includes removing the external terminal of the terminal and removing the overmolded feature. In some cases where a fully enclosed connector is used, reinserting (908) at least a portion of the overmolded feature or terminal includes reinserting the overmolded feature and reattaching the external terminal of the terminal, and reattaching (910) the electrical connection to the terminal includes reattaching the fully enclosed connector to the external terminal.

[0046] In some cases, replacing the (906) fuse involves replacing the fuse with a fuse of the same type. In some cases, replacing the (906) fuse with a fuse of the same type involves positioning the fuse of the same type around an internal terminal; that is, the internal terminal is used to facilitate positioning the fuse of the same type in the correct position (e.g., below the external terminal and / or overmolded features and around at least a portion of the internal terminal).

[0047] In some cases, re-inserting (908) at least a portion of the overmolded feature or terminal includes “clamping” the overmolded feature into place (e.g., around at least a portion of the external terminal and within a post of the corresponding terminal assembly). In some cases, method 900 further includes: removing the O-ring before disconnecting (902) the fully enclosed connector from the external terminal and / or removing (904) at least a portion of the overmolded feature and / or terminal and / or post; and re-inserting the O-ring after re-inserting (908) at least a portion of the overmolded feature and / or terminal and reattaching (910) the fully enclosed connector to the external terminal and / or post to provide sufficient pressure during normal use of the power electronic device to hold the overmolded feature in place.

[0048] In some cases using a ring connector, disconnecting (902) the electrical connection includes removing the terminal locking mechanism and the terminal wire connection mechanism (e.g., ring connector) from the terminal. In some cases using a ring connector, reattaching (910) the electrical connection to the terminal includes reattaching the terminal wire connection and reattaching the terminal locking mechanism to the terminal.

[0049] In some cases, replacing the (906) fuse involves replacing the fuse with one of the same type. In some cases, replacing the (906) fuse with one of the same type involves positioning the same type of fuse around a terminal; that is, the terminal is used to facilitate positioning the same type of fuse in the correct position (e.g., at least a portion of the terminal is below the overmolded feature). In some cases, re-inserting the (908) overmolded feature or at least a portion of the terminal involves “clamping” the overmolded feature into place (e.g., around at least a portion of the terminal and within the post of the corresponding terminal assembly). In some cases, method 900 further includes: removing the O-ring before removing at least a portion of the (904) overmolded feature or terminal; and re-inserting the O-ring after re-inserting the (908) overmolded feature or terminal to provide sufficient pressure during normal use of the power electronic equipment while holding the overmolded feature in place.

[0050] In some cases using the RD8 connector, disconnecting (902) the electrical connection includes removing the RD8 connector from the external terminal, and removing (904) at least a portion of the overmolded feature or terminal includes removing the external terminal of the terminal and removing the overmolded feature. In some cases using the RD8 connector, reinserting (908) at least a portion of the overmolded feature or terminal includes reinserting the overmolded feature and reattaching the external terminal of the terminal, and reattaching (910) the electrical connection to the terminal includes reattaching the RD8 connector to the external terminal.

[0051] In some cases, replacing the (906) fuse involves replacing the fuse with a fuse of the same type. In some cases, replacing the (906) fuse with a fuse of the same type involves positioning the fuse of the same type around an internal terminal; that is, the internal terminal is used to facilitate positioning the fuse of the same type in the correct position (e.g., below the external terminal and / or overmolded features and around at least a portion of the internal terminal).

[0052] In some cases, re-inserting (908) at least a portion of the overmolded feature or terminal includes "clicking" the overmolded feature around at least a portion of the external terminal and into place within the post of the respective terminal assembly. In some cases, method 900 further includes: removing the O-ring before disconnecting (902) the RD8 connector and / or removing (904) at least a portion of the overmolded feature and / or terminal and / or post, and re-inserting the O-ring 428 after re-inserting (908) at least a portion of the overmolded feature and / or terminal and / or reattaching (910) the RD8 connector and / or post to provide sufficient pressure during normal use of the power electronic equipment and / or system to hold the overmolded feature in place.

[0053] Figures 10A to 10C illustrate comparators for testing the voltage or current on either side of a fuse in a power electronic device and / or system. Referring to Figures 10A to 10C, comparator 1000 is electrically coupled to a first test point 1002 and a second test point 1004. The first test point 1002 is located in a first electrical path 1006 passing through fuse 1008 between terminal 1010 and power electronic circuit 1012, and the second test point 1004 is located in a second electrical path 1016 passing through fuse 1008 between terminal 1010 and power electronic circuit 1012. In some cases, comparator 1000 may be located and / or formed within power electronic circuit 1012 and / or a printed circuit board (PCB).

[0054] Comparator 1000 receives a first current or voltage value from a first test point 1002 and a second current or voltage value from a second test point 1004. The first test point 1002 is located in a first electrical path 1006 passing through a fuse 1008 between the terminal 1010 and the power electronic circuit 1012. The second test point 1004 is located in a second electrical path 1016 passing through a fuse 1008 between the terminal 1010 and the power electronic circuit 1012.

[0055] In some cases, the first test point 1002 is located on the first electrical path 1006 on one side of the fuse 1008, and the second test point 1004 is located on the second electrical path 1016 on the opposite side of the fuse 1008. In other cases, the first test point 1002 is located on the first electrical path 1006 before power reaches the fuse 1008, and the second test point 1004 is located on the second electrical path 1016 after power passes through the fuse 1008. The comparator 1000 can determine whether the fuse 1008 is operable based on a first current or voltage value and a second current or voltage value. For example, the comparator 1000 can receive a first current or voltage value from the first test point 1002 that is equal to a second current or voltage value from the second test point 1004, and determine that the fuse 1008 is operable. For example, comparator 1000 may receive a first current or voltage value from first test point 1002 that differs from a second current or voltage value from second test point 1004, and determine that fuse 1008 is unavailable. As a specific example, comparator 1000 may receive a non-zero and / or positive first current or voltage value from first test point 1002 and a zero second current or voltage value from second test point 1004, and determine that fuse 1008 is unavailable. In this example, the second current or voltage value from second test point 1004 is zero.

[0056] In some cases, a fuse availability indicator (not shown) is coupled to receive a determination of whether fuse 1008 is available. For example, when the received determination is that fuse 1008 is available, the fuse availability indicator can be turned on, and when the received determination is that fuse 1008 is unavailable, the fuse availability indicator can be turned off. As another example, when the received determination is that fuse 1008 is available, the fuse availability indicator can change to a specific color (e.g., green), and when the received determination is that fuse 1008 is unavailable, the fuse availability indicator can change to a different specific color (e.g., red). As yet another example, when the received determination is that fuse 1008 is available, the fuse availability indicator can be turned off, and when the received determination is that fuse 1008 is unavailable, the fuse availability indicator can be turned on. In some cases, comparator 1000 is used in DC / DC converters. In some cases, comparator 1000 is used in other types of converters, inverters, electric heaters, and / or battery systems.

[0057] Figure 11 shows a cross-sectional view of an embodiment with current flowing through a terminal assembly and a replaceable fuse located outside the power electronic system. The current flow (e.g., indicated by the arrows in the first electrical path 1126) is the power output path of the terminal assembly; however, in the power input path of the terminal assembly, the current flow is reversed in the first electrical path 1126. Referring to Figure 11, a terminal assembly 1100 of a power electronic device and / or system includes a terminal 1102 and a fuse 1104. Terminal 1102 may include an external terminal 1106 and an internal terminal 1108. The fuse 1104 may be positioned about at least a portion of the internal terminal 1108. In some cases, terminal 1102 is a single piece and / or integral.

[0058] In some cases, the overmolded feature (not shown in the figure) is positioned around at least a portion of the outer terminal 1106 and within the post 1110 of the terminal assembly 1100. In some cases, the terminal assembly 1100 includes an O-ring (not shown in the figure) to provide sufficient pressure during normal use of the power electronic device and / or system to hold the overmolded feature and / or post 1110 in place. The O-ring may be located between the post 1110 and the connector block 1112 of the terminal assembly 1100.

[0059] Power electronic circuit 1114 is electrically coupled to internal terminal 1108. In some cases, power electronic circuit 1114 is a printed circuit board (PCB). A hermetically sealed housing 1116 of the power electronic device and / or system is also shown. Internal terminal 1108 of terminal 1102 is electrically coupled to power electronic circuit 1114, and power electronic circuit 1114 is arranged within hermetically sealed housing 1116 and electrically connected via external terminal 1106 and / or internal terminal 1108 extending out of hermetically sealed housing 1116. Fuse 1104 is arranged outside hermetically sealed housing 1116 and is electrically coupled to power electronic circuit 1114 as well as external terminal 1106 and / or internal terminal 1108. A comparator (e.g., not shown, but described with reference to Figures 10A to 10C) is also arranged within hermetically sealed housing 1116. In some cases, the comparator is formed as part of power electronic circuit 1114.

[0060] Power input and power output can be supplied / implemented via ring terminal connectors, fully enclosed connectors, post connectors, RD8 connectors, RD8 connectors on the harness side and / or any other type of connector used to couple wiring to terminal assembly 1100.

[0061] The comparator is electrically coupled to a first test point 1118 and a second test point 1120. The first test point 1118 is located in a first electrical path 1122 passing through a fuse 1104 between terminal 1102 and power electronic circuit 1114, and the second test point 1120 is located in a second electrical path 1124 passing through a fuse 1104 between terminal 1102 and power electronic circuit 1114. In some cases, the comparator may be located and / or formed within power electronic circuit 1114. In some cases, the comparator is separate from power electronic circuit 1114.

[0062] As described above with reference to Figures 10A to 10C, the comparator receives a first current or voltage value from a first test point 1118 and a second current or voltage value from a second test point 1120. The first test point 1118 is located on a first electrical path 1122 passing through a fuse 1104 between the terminal 1102 and the power electronic circuit 1114, and the second test point 1120 is located in a second electrical path 1124 passing through a fuse 1104 between the terminal 1102 and the power electronic circuit 1114.

[0063] In some cases, the comparator is configured to determine whether fuse 1104 is usable based on a first current or voltage value and a second current or voltage value. For example, the comparator may receive a first current or voltage value from a first test point 1118 that is equal to a second current or voltage value from a second test point 1120, and determine that fuse 1104 is usable. As another example, the comparator may receive a first current or voltage value from a first test point 1118 that is different from a second current or voltage value from a second test point 1120, and determine that fuse 1104 is not usable. As a specific example, the comparator may receive a non-zero and / or positive first current or voltage value from a first test point 1118 and a zero second current or voltage value from a second test point 1120, and determine that fuse 1104 is not usable. In any case, if fuse 1104 is determined to be unusable, fuse 1104 can be replaced by method 900 described with reference to FIG. 9.

[0064] In some cases, a fuse availability indicator (not shown) is coupled to receive a determination of whether fuse 1104 is available. For example, the fuse availability indicator may be on when the received determination is that fuse 1104 is available, and off when the received determination is that fuse 1104 is unavailable. As another example, the fuse availability indicator may change to a specific color (e.g., green) when the received determination is that fuse 1104 is available, and to a different specific color (e.g., red) when the received determination is that fuse 1104 is unavailable. As yet another example, the fuse availability indicator may be off when the received determination is that fuse 1104 is available, and on when the received determination is that fuse 1104 is unavailable. In some cases, comparators are used in DC / DC converters. In some cases, comparators are used in other types of converters, inverters, electric heaters, and / or battery systems.

[0065] Figure 12 shows a cross-sectional view of an embodiment of a terminal assembly and a replaceable fuse located outside the power electronics system receiving a fully enclosed connector. Referring to Figure 12, the terminal assembly 1200 includes a terminal 1202, a fuse 1204, a conductive element 1206, a power electronic circuit 1208, and a fully enclosed connector 1210. The terminal assembly 1200 also includes an overmolded feature (not shown in these figures). The fuse 1204 may be located below the overmolded feature and / or a portion of the terminal 1202 (e.g., the outer terminal 1212 of the terminal 1202) and positioned around at least a portion of the terminal 1202 (e.g., the inner terminal 1214 of the terminal 1202). The fuse 1204 is also located outside a hermetically sealed housing 1220. The power electronic circuit 1208 is arranged within the hermetically sealed housing 1220 and provides electrical access via the terminal 1202 extending out of the hermetically sealed housing 1220.

[0066] Terminal assembly 1200 also includes a post 1216, a connector block 1218, and a sealing housing 1220. In some cases, an O-ring (not shown in the figure) is included in terminal assembly 1200 to provide sufficient pressure during normal use of the power electronic device and / or system to hold the overmolded feature and / or post 1216 in place. The O-ring may be located between post 1216 and connector block 1218 of terminal assembly 1200. In some cases, power electronic circuit 1208 is a printed circuit board (PCB).

[0067] In this embodiment, the current flow (e.g., indicated by the arrow in the first electrical path 1222) is the power output path of the terminal assembly 1200; however, in the power input path of the terminal assembly 1200, the current flow will be reversed in the first electrical path 1222. A comparator (e.g., not shown, but described with reference to Figures 10A to 10C) is also arranged within the hermetically sealed housing 1220. In some cases, the comparator is formed as part of the power electronic circuit 1208. The comparator is electrically coupled to a first test point 1224 and a second test point 1226. The first test point 1224 is located in the first electrical path 1222 passing through the fuse 1204 between the terminal 1202 and the power electronic circuit 1208, and the second test point 1226 is located in the second electrical path 1228 passing through the fuse 1204 between the terminal 1202 and the power electronic circuit 1208. In some cases, the comparator may be located and / or formed within the power electronic circuit 1208. In some cases, the comparator is separate from the power electronic circuit 1208. The comparator is configured to determine the availability of the fuse 1204 as described above with reference to Figures 10A to 10C and Figure 11.

[0068] Figure 13 shows a cross-sectional view of an embodiment of a terminal assembly and a replaceable fuse located outside the power electronics system receiving the ring connector. Referring to Figure 13, the terminal assembly 1300 includes a terminal 1302, a fuse 1304, a conductive element 1306, a power electronic circuit 1308, and a ring connector 1310. The terminal assembly 1300 also includes an overmolded feature 1309. The fuse 1304 may be located below the overmolded feature 1309 and / or a portion of the terminal 1302, and positioned around at least a portion of the terminal 1302. The fuse 1304 is also located outside a hermetically sealed housing 1320. The power electronic circuit 1308 is arranged within the hermetically sealed housing 1320 and provides electrical access via the terminal 1302 extending out of the hermetically sealed housing 1320. A terminal locking mechanism 1312, such as a nut, is included to secure and / or electrically couple the ring connector 1310 to the terminal 1302.

[0069] Terminal assembly 1300 also includes a post 1316, a connector block 1318, and a sealing housing 1320. In some cases, an O-ring 1321 is included in terminal assembly 1300 to provide sufficient pressure during normal use of the power electronic equipment and / or system to hold the overmolded feature 1309 and / or post 1316 in place. The O-ring may be located between post 1316 and connector block 1318 of terminal assembly 1300. In some cases, power electronic circuit 1308 is a printed circuit board (PCB).

[0070] In this embodiment, the current flow (e.g., indicated by the arrow in the first electrical path 1322) is the power output path of the terminal assembly 1300; however, in the power input path of the terminal assembly 1300, the current flow will be reversed in the first electrical path 1322. A comparator (e.g., not shown, but described with reference to Figures 10A to 10C) is also arranged within the hermetically sealed housing 1320. In some cases, the comparator is formed as part of the power electronic circuit 1308. The comparator is electrically coupled to a first test point 1324 and a second test point 1326. The first test point 1324 is located in the first electrical path 1322 passing through the fuse 1304 between the terminal 1302 and the power electronic circuit 1308, and the second test point 1326 is located in the second electrical path 1328 passing through the fuse 1304 between the terminal 1302 and the power electronic circuit 1308. In some cases, the comparator may be located and / or formed within the power electronic circuit 1308. In some cases, the comparator is separate from the power electronic circuit 1308. The comparator is configured to determine the availability of the fuse 1304 as described above with reference to Figures 10A to 10C and Figure 11.

[0071] Figure 14 shows a cross-sectional view of an embodiment of a terminal assembly and a replaceable fuse located outside the power electronics system receiving an RD8 connector. Referring to Figure 14, the terminal assembly 1400 includes a terminal 1402, a fuse 1404, a conductive element 1406, a power electronic circuit 1408, and an RD8 connector 1410. The terminal assembly 1400 also includes an overmolded feature 1409. The fuse 1404 may be located below the overmolded feature 1409 and / or a portion of the terminal 1402 (e.g., the outer terminal 1412 of the terminal 1402) and positioned around at least a portion of the terminal 1402 (e.g., the inner terminal 1414 of the terminal 1402). The fuse 1404 is also located outside a hermetically sealed housing 1420. The power electronic circuit 1408 is arranged within the hermetically sealed housing 1420 and provides electrical access via the terminal 1402 extending out of the hermetically sealed housing 1420.

[0072] Terminal assembly 1400 also includes post 1416, connector block 1418, and sealing housing 1420. In some cases, terminal assembly 1400 includes O-ring 1419 to provide sufficient pressure during normal use of the power electronic equipment and / or system to hold overmolded feature 1409 and / or post 1416 in place. O-ring 1419 may be located between post 1416 and connector block 1418 of terminal assembly 1400. In some cases, power electronic circuit 1408 is a printed circuit board (PCB).

[0073] In this embodiment, the current flow (e.g., indicated by the arrow in the first electrical path 1422) is the power output path of the terminal assembly 1400; however, in the power input path of the terminal assembly 1400, the current flow will be reversed in the first electrical path 1422. A comparator (e.g., not shown, but described with reference to Figures 10A to 10C) is also arranged within the hermetically sealed housing 1420. In some cases, the comparator is formed as part of the power electronic circuit 1408. The comparator is electrically coupled to a first test point 1424 and a second test point 1426. The first test point 1424 is located in the first electrical path 1422 passing through the fuse 1404 between the terminal 1402 and the power electronic circuit 1408, and the second test point 1426 is located in the second electrical path 1428 passing through the fuse 1404 between the terminal 1402 and the power electronic circuit 1408. In some cases, the comparator may be located and / or formed within the power electronic circuit 1408. In some cases, the comparator is separate from the power electronic circuit 1408. The comparator is configured to determine the availability of the fuse 1404 as described above with reference to Figures 10A to 10C and Figure 11.

[0074] Clause 1. A system comprising: a power electronic circuit; a terminal for electrically coupling to the power electronic circuit; a hermetically sealed housing wherein the power electronic circuit is disposed within the hermetically sealed housing and electrically connected via the terminal extending out of the hermetically sealed housing; a fuse disposed outside the hermetically sealed housing, wherein the fuse is electrically coupled to the power electronic circuit and the terminal; and a comparator disposed within the hermetically sealed housing, the comparator being coupled to receive a first current or voltage value from a first test point and a second current or voltage value from a second test point, the first test point being located on a first electrical path through the fuse between the terminal and the power electronic circuit, and the second test point being located on a second electrical path through the fuse between the terminal and the power electronic circuit.

[0075] Clause 2. The system according to Clause 1, wherein the comparator is configured to determine whether the fuse is available based on the first current or voltage value and the second current or voltage value.

[0076] Clause 3. The system according to Clause 1 or 2 further includes a fuse availability indicator coupled to receive a determination of whether the fuse is available.

[0077] Clause 4. The system according to any one of Clauses 1 to 3 further includes a conductive element that electrically couples the fuse to the power electronic circuit.

[0078] Clause 5. The system according to any one of Clauses 1 to 4, wherein the system is a converter, inverter, electric heater or battery.

[0079] Clause 6. The system according to any one of Clauses 1 to 5, wherein the terminal comprises: an external terminal for attachment to a connector; and an internal terminal coupled to the external terminal for attachment to the power electronic circuit.

[0080] Clause 7. The system according to any one of Clauses 1 to 6, wherein, when attached to the external terminals, the internal terminals provide compressive force to the power electronic circuit.

[0081] Clause 8. The system according to any one of Clauses 1 to 7, wherein the internal terminal is attached to the external terminal via press fit.

[0082] Clause 9. The system according to any one of Clauses 1 to 8, wherein the internal terminal includes a longitudinal shaft and an enlarged head attached to the end of the longitudinal shaft.

[0083] Clause 10. The system according to any one of Clauses 1 to 9 further includes an overmolded feature positioned around the external terminal and above the fuse.

[0084] Clause 11. The system according to any one of Clauses 1 to 10, wherein the connector is a ring connector.

[0085] Clause 12. The system according to any one of Clauses 1 to 11, wherein the connector is a fully enclosed connector.

[0086] Clause 13. The system according to any one of Clauses 1 to 12, wherein the connector is an RD8 connector.

[0087] Clause 14. The system according to any one of Clauses 1 to 13 further includes a spring force element, wherein the fuse is electrically coupled to the terminal via the spring force element.

[0088] Clause 15. A method of replacing a fuse in a power electronic system, the method comprising: disconnecting an electrical connection from a terminal; removing an overmolded feature or at least a portion of the terminal; replacing the fuse, wherein the fuse is located outside a sealed housing of the power electronic system; re-inserting the overmolded feature or at least a portion of the terminal; and reattaching the electrical connection to the terminal.

[0089] Clause 16. The method according to Clause 15, wherein removing the overmolded feature or the at least portion of the terminal comprises: removing the outer terminal of the terminal; removing the overmolded feature; wherein re-inserting the overmolded feature or the at least portion of the terminal comprises: re-inserting the overmolded feature; and reattaching the outer terminal of the terminal.

[0090] Clause 17. The method according to Clause 15 or 16, further comprising: removing the O-ring before removing the overmolded feature or the at least portion of the terminal; and reinserting the O-ring after reinserting the overmolded feature or the at least portion of the terminal.

[0091] Clause 18. The method according to any one of Clauses 15 to 17, wherein the electrical connection comprises a ring connector.

[0092] Clause 19. The method according to any one of Clauses 15 to 18, wherein the electrical connection comprises a fully enclosed connector.

[0093] Clause 20. The method according to any one of Clauses 15 to 19, wherein the electrical connection comprises an RD8 connector.

[0094] Although the subject matter has been described in language specific to structural features and / or actions, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or actions described above. Rather, the specific features and actions described above are disclosed as examples of implementing the claims, and other equivalent features and actions are intended to fall within the scope of the claims.

Claims

1. A system comprising: Power electronic circuits; Terminals, the terminals being used for electrical coupling to the power electronic circuit; A sealed housing, wherein the power electronic circuitry is disposed within the sealed housing and electrically connected via terminals extending out of the sealed housing; a fuse, disposed outside the sealed housing, wherein the fuse is electrically coupled to the power electronic circuitry and the terminals; The comparator is disposed within the sealed housing and coupled to receive a first current or voltage value from a first test point and a second current or voltage value from a second test point, the first test point being located on a first electrical path through the fuse between the terminal and the power electronic circuit, and the second test point being located on a second electrical path through the fuse between the terminal and the power electronic circuit.

2. The system according to claim 1, wherein, The comparator is configured to determine whether the fuse is available based on the first current or voltage value and the second current or voltage value.

3. The system of claim 2, further comprising a fuse availability indicator, the fuse availability indicator being coupled to receive a determination of whether the fuse is available.

4. The system of claim 2, further comprising a conductive element that electrically couples the fuse to the power electronic circuit.

5. The system according to claim 1, wherein, The system is a converter, inverter, electric heater, or battery.

6. The system according to claim 1, wherein, The terminal includes: an external terminal for attachment to a connector; and an internal terminal coupled to the external terminal for attachment to the power electronic circuit.

7. The system according to claim 6, wherein, When attached to the external terminal, the internal terminal provides compressive force to the power electronic circuit.

8. The system according to claim 7, wherein, The internal terminal is attached to the external terminal via a press fit.

9. The system according to claim 8, wherein, The internal terminal includes a longitudinal shaft and an enlarged head attached to the end of the longitudinal shaft.

10. The system of claim 6, further comprising an overmolding feature positioned around the external terminal and above the fuse.

11. The system according to claim 6, wherein, The connector is a ring connector.

12. The system according to claim 6, wherein, The connector is a fully enclosed connector.

13. The system according to claim 6, wherein, The connector is an RD8 connector.

14. The system of claim 1, further comprising a spring force element, wherein the fuse is electrically coupled to the terminal via the spring force element.

15. A method for replacing a fuse in a power electronic system, the method comprising: Disconnect the electrical connection from the terminal; Remove at least a portion of the overmolded feature or the terminal; Replace the fuse, wherein the fuse is located outside the sealed housing of the power electronic system; re-insert the overmolded feature or the at least portion of the terminal; and reattach the electrical connection to the terminal.

16. The method according to claim 15, wherein, Removing the overmolded feature or at least a portion of the terminal includes: removing the outer terminal of the terminal; removing the overmolded feature; wherein re-inserting the overmolded feature or at least a portion of the terminal includes: re-inserting the overmolded feature; and reattaching the outer terminal of the terminal.

17. The method according to claim 15, further comprising: Remove the O-ring before removing the overmolded feature or at least a portion of the terminal; And after re-inserting the overmolded feature or the terminal at least a portion thereof, the O-ring is re-inserted.

18. The method according to claim 15, wherein, The electrical connection includes a ring connector.

19. The method according to claim 15, wherein, The electrical connection includes a fully enclosed connector.

20. The method of claim 15, wherein, The electrical connection includes an RD8 connector.

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