Modular electronic fuses and fuse box

Abstract

The invention relates to an architecture of a set (100) consisting of a number n of electronic fuses (S1, S2, S3, ..., Sn) for controlled separation and connection of one or more electronic circuits ik or channels having one of the fuses (S1, S2, S3, ..., Sn), wherein each fuse (S1, S2, S3, ..., Sn) has a fuse housing (10) and a connection base (20) having connection contacts (E, A), wherein these have an input contact (E) and output contacts (A1, A2, A3, ..., AK) for each circuit ik or channel k to be switched, which output contacts have, in terms of circuitry, at least one carrier structure / printed circuit board (32) integrated in each fuse (S1, S2, S3, ..., Sn) and equipped with electronic switching elements (31) and are each connected, in terms of circuitry, to the input contact (E).

Description

[0001] Modular electronic fuses and fuse box

[0002] Description:

[0003] The invention relates to a flexibly adaptable architecture of a modular solution for electronic fuses (eFuse) for protecting electronic circuits, preferably in a vehicle electrical system, as well as a fuse box that can be modularly equipped with such electronic fuses. In addition to vehicle applications and electrical systems, the invention also relates to other electronic applications in which a variable number of circuits must be flexibly protected.

[0004] Various fuses are already known in the state of the art for isolating electrical circuits. Traditionally, fuses are still used, but they have many disadvantages and are each set to a specific, fixed shutdown condition, such as a maximum permissible current. If the permissible current is exceeded, the fuse wire melts, and the fuse is no longer functional.

[0005] Especially in motor vehicles, electrical consumers are typically located in an on-board electrical system. A distinction is made between safety-relevant consumers and non-safety-relevant consumers, such as quality management (QM) consumers. During operation of the on-board electrical system, it is important that the power supply, especially for safety-relevant consumers, is always secure and guaranteed. To ensure the safety of the on-board electrical system, it is well known that the power supply in the on-board electrical system and thus in the vehicle must be monitored. In principle, there is a requirement to meet functional safety requirements (ISO 26262).

[0006] Fig. 1 of DE 102020213357 A1 shows a possible topology of a power supply system, consisting of a base electrical system, which includes an energy storage device with an associated battery sensor, as well as several consumers that are protected or controlled by an electronic load distributor. The electronic load distributor comprises several switching devices, each of which controls or protects, in particular, safety-relevant consumers. The semiconductor switches function, for example, according to certain criteria, such as overvoltage, (over)current, temperature, etc., as electronic fuses to disconnect the respective protected consumer from the power supply in the event of impermissible operating conditions.

[0007] For example, another load distributor is connected to the switching device of the electronic load distributor, through which additional consumers are protected (e.g., via fuses) and supplied with power in a targeted manner. These consumers could be, for example, lighting, windshield wipers, or consumers that are activated after a vehicle crash. Furthermore, the electronic load distributor includes a disconnecting device to isolate the electronic load distributor from the sub-vehicle electrical system.

[0008] However, the load distributor and the switching devices have a fixed topology tailored to the on-board electrical system, and this topology cannot be flexibly transferred to other on-board electrical systems. Thus, for a number of different vehicles, even those from the same manufacturer, a large number of load distributors and fuse boxes are required to match the respective vehicle configuration. This is disadvantageous and complex.

[0009] DE 4329860 A1 discloses a circuit for controlling various electrical loads in a motor vehicle. The solution relates to a circuit arrangement for controlling various electrical loads in a motor vehicle. The circuit arrangement is connected on the input side to a voltage source and input switches, and on the output side to the loads to be controlled. Each load is assigned an individual semiconductor element, which disconnects the associated load from the voltage source when a short circuit occurs at the semiconductor element output and reconnects the associated load to the voltage source when the short circuit is resolved. A semiconductor element is also provided for controlling loads that consume relatively high electrical power in the motor vehicle, such as a passenger compartment heater. MOSFET transistors are used in particular as semiconductor components.

[0010] Here, too, the switching elements and safety devices are permanently installed in the circuit, so that variable adaptation to different on-board networks or requirements is not easily possible.

[0011] The publications DE 102005013440 A, JP 2007288356 and EP 1870978 A show further alternative, but also inflexible solutions, each of which is statically tailored to a specific application.

[0012] In addition to the fundamental need for greater variability and flexibility, there is another need for the ability to adapt or modify a fuse box or fuse architecture, especially after installation in an application or vehicle electrical system. It would also be desirable to be able to enable and disable certain loads and devices without a specific shutdown condition occurring during use.

[0013] It is well known that vehicle configuration involves considerable effort if the customer requires certain components in the vehicle that are intended as accessories or special equipment. On the one hand, the configuration cannot be changed later, and on the other hand, there are features that one may want to be able to activate depending on user behavior during operation, for example, by paying a fee.

[0014] With the solutions known in the state of the art, such flexible, variable and even adaptable solutions during operation cannot be implemented in the desired manner.

[0015] It is therefore an object of the present invention to overcome the disadvantages existing in the prior art and in particular to propose a cost-effective, adaptable and flexible solution with which a large number of applications, in particular security concepts, can be implemented in a vehicle electrical system.

[0016] According to the invention, a set consisting of a plurality n electronic fuses (S1, S2, S3, ..., Sn) for the controlled separation and connection of one or more electronic circuits or channels to one of the fuses is proposed, wherein each fuse has a fuse housing and a connection base with connection contacts. According to the invention, these have exactly one or at least one input contact and, for each circuit or channel to be switched, correspondingly k output contacts, which are circuit-wise connected via at least one printed circuit board (or a carrier structure which has conductive elements / conductor tracks) integrated in the respective fuse and which is equipped with electrical switching elements and which is each circuit-wise connected to the input contact, wherein the following conditions apply: new with n > 4 and ke N with k = 1, 2, 3 to n.

[0017] The number n of electronic fuses is advantageous in the range of 10 to 50, and in any case greater than or equal to 4, as this allows modularity to be achieved particularly efficiently. Modular concepts are known in the state of the art, but according to the present idea, the combination of modularity at the fuse level (modular electronic fuse with multiple channels) on the one hand and, in addition, modularity at the variant level (fuses of different designs) on the other hand, allows a significantly higher number of solutions to be implemented according to the modular principle with a significantly smaller number of provided variants. Here, the multi-channel variants themselves are already particularly versatile, as these solutions enable modularity in a first (higher-level) hierarchy as well as modularity in a lower-level hierarchy (at the fuse level).The concept of the present invention therefore consists in the optimization and realization of the following components:.

[0018] - modular design of electronic fuses (single / double / quadruple / ... / multi-channel),

[0019] - Modular system consisting of modular fuses and variants,

[0020] - Possibility of combining different performance classes of the known classes of plug-in fuses from typically 1 to 80A or screw-in fuses from typically 80 to 400A

[0021] - At the same time, the possibility of a flexible, adaptable and modular design of electronic fuse boxes (ePDU / eHSB) with the combination of individual plug-in modules, variants and the combination of other electrical modules on a common circuit board.

[0022] In a further advantageous embodiment of the invention, the connection contacts are designed as plug-in contacts, solder contacts, or press-in contacts with a common mounting direction or extension direction. This allows for the creation of particularly easy-to-assemble and clearly arranged boxes in which all fuses can be fixed in one mounting plane and mounted, for example, by inserting them into the plug-in contacts.

[0023] A further optional development of the invention provides that the connection contacts are designed with an opening for screwing, in order to electrically connect them to an electrical circuit using a screwable connection means. For example, busbar or busbar connections with a screw solution are conceivable. It is also advantageous if the connection contacts intended for screwing are arranged on opposite sides of the electrical fuses or protrude.

[0024] It is further advantageous if the or all switching elements of the electronic fuses (S1, S2, S3, ..., Sn) can be individually adjusted in their disconnection and switching conditions, in particular if they can be programmed or adapted via an integrated communication interface.

[0025] Another aspect of the present invention relates to the design of the connections. It is advantageous that the input contact has a current-carrying capacity that corresponds to the sum of the current-carrying capacities of the plug contacts or is at least 60 - 80% of the sum thereof. In this way, for example, a channel can be switched off (load shedding) and the current flowing through the input contact can be distributed among the remaining channels or only directed via a safety-relevant circuit, i.e. one channel (if there is a temporarily higher current demand there). This function can be required, for example, if a circuit is to be reliably supplied to ensure the stability of the on-board electrical system, but no current needs to flow in another circuit protected by the same fuse. This dynamic adaptability represents a particular advantage over conventional solutions.

[0026] One possible implementation provides that the input contact is geometrically designed with a cross-section equal to or larger than the sum of the respective cross-sections of the plug contacts defined as outputs.

[0027] It is further advantageous if the or all switching elements of the respective electronic fuses can be individually activated or deactivated even when installed in the intended operation, regardless of whether a specific disconnection or switching condition has occurred in the vehicle electrical system.

[0028] Also advantageous is a solution in which the disconnection or switching condition of one, several or all electronic switching elements represents either a current threshold or a voltage threshold, wherein in particular a switch-off condition is provided to ensure that the vehicle electrical system voltage remains stable and that, in the event of an excessive voltage drop in a circuit or load circuit, the switching element in question is switched to its disconnected position.

[0029] A further aspect of the present invention relates to a fuse box designed or comprising a plurality of interfaces, in particular connection sockets designed for connection to a selection of electronic fuses selected or selectable from the set of electronic fuses as described above.

[0030] It is also advantageous if the fuse box is designed to accommodate a mix of electronic fuses and other conventional fuse types, such as melting fuses.

[0031] Other advantageous developments of the invention are characterized in the subclaims or are presented in more detail below together with the description of the preferred embodiment of the invention with reference to the figures.

[0032] Shown are: Fig. 1 electronic fuse designed as a plug-in module 20 - 40 A, 1 -way (ie for one protection channel or circuit);

[0033] Fig. 2 electronic fuse designed as a plug-in module 20 - 40 A, 4-way (ie for 4 protection channels or circuits);

[0034] Fig. 3 electronic fuse designed as a plug-in module 1 - 20 A, 4-way (ie for 4 protection channels or circuits);

[0035] Fig. 4 electronic fuse designed as a screw module 40 - 400 A, 6-way (ie for 6 protection channels or circuits) and

[0036] Fig. 5 shows a hybrid fuse box with a selection of fuses from the set Sn according to the invention.

[0037] The figures are schematic examples. The invention is described in more detail below with reference to the figures, wherein like reference numerals in the figures indicate like functional and / or structural features.

[0038] Figure 1 shows an electronic fuse S1 designed as a plug-in module for 20 - 40 A, 1 -way, ie for protecting one circuit or channel that runs from the input E via a switching element 31 on the printed circuit board 30 to the output A1. This exemplary fuse S1, selected from the set 100 consisting of a plurality of n electronic fuses S1, S2, S3, ..., Sn for the controlled separation and connection of one or more electronic circuits ik or channels, furthermore has a fuse housing 10 and a connection base 20 (plug-in base) with the two connection contacts E, A1. Furthermore, the fuse S1 has a communication interface 50 with a plurality of signal contacts 51 for data transmission and communication with the fuse S1. For this purpose, the fuse S1 has corresponding electronic components 33 that are arranged on the printed circuit board 32.As can also be seen in Figure 1, the contacts E, A1, 51 each have a plug-side contact end 34, which can be plugged into a corresponding contact socket 61 on a mating plug base 60. At the opposite end of the respective contacts E, A1, 51 are circuit board-side contact ends 34 for contacting the circuit board 32. Furthermore, corner-side bearing and holding means 22 for supporting and laterally holding the circuit board 32 are provided on the connection base 20. Furthermore, contact bearing blocks 22 are provided on the side facing the circuit board 32, through which the respective circuit board-side contact ends 34 protrude or protrude.

[0039] As can also be clearly seen in Figure 1, the contact geometry on the plug-in side of contacts E, A1, and S1 is designed differently, with the flat contacts E, A1 forming pin contact sections, preferably pin contact sections with a round or square cross-section. In this respect, a fuse with an optimized contact design is also proposed.

[0040] The circuit board can be populated on both sides thanks to the corner support blocks 22. At the upper end of the corner support blocks 22 are L-shaped corner bracket sections that serve as stops for the circuit board 32.

[0041] In Figure 2, an electronic fuse S2 is designed as a plug-in module for 1 - 20 A, 4-way, ie for protecting four circuits. One of the contacts represents the input contact E. Furthermore, four output contacts A1, A2, A3, A4 are provided, which are provided for each circuit ik (ii, i2, is, 14) or channel k to be switched and are connected to the input contact E via at least one circuit board 32 integrated in the fuse S2 and equipped with electronic switching elements 31. Otherwise, the topology of the fuse S2 is similar to the topology of the fuse S1 from Figure 1.

[0042] Figure 3 shows a fuse similar to Figure 2, but configured for different currents. Otherwise, the reference numerals refer to the features already explained.

[0043] Figure 4 shows an alternative solution for an electronic fuse S4, the fuse design (and thus the structure inside the fuse housing 10) of which is conceptually analogous to the fuses S1 to S3. The connection base(s) 20 are divided on both sides on the two opposite long sides and provided with the connection contacts E, A1 - A6, whereby the connection contacts E, A1 - A6 are designed as screw solutions and therefore form an opening 22 that serves for screwing. It can also be seen that the connection cross-section of the output contacts A1 and A2 to A6 is designed differently. The total current that is distributed via the input contact E to all output contacts A1 to A6 can, for example, also be conducted only via the output contact A1, which has been configured to be sufficiently large for this purpose (similar to the input contact E).Furthermore, the fuse S4 has a communication interface 50 with several (not shown) signal contacts for data transmission and communication of the fuse S1 with an external device, for example a control unit.

[0044] Figure 5 shows a hybrid fuse box 200 configured to be equipped with a number of electronic fuses S2, S5, and S6 (from the set 100). Additionally (but not necessarily), conventional plug-in sockets for fuses 2 can also be provided. Furthermore, an optional electronic module M1 is designed to be pluggable and plugged into a corresponding plug-in socket.

[0045] The fuse box 200 according to the invention can also be designed as a non-hybrid solution. Furthermore, the invention can be used analogously in distribution boxes or load distributors, EM boxes, backup fuse boxes, or main fuse boxes, so that the term "fuse box" in the sense of the invention is generally understood to mean a fuse box in which a number of different electronic fuses Sn are used.

[0046] The invention is not limited in its implementation to the preferred embodiments specified above. Rather, a number of variants are conceivable, which utilize the illustrated solution even in fundamentally different embodiments. Thus, according to the concept of the invention, the set 100 is not limited to the illustrated variants, but can comprise a multitude of additional electronic fuses Sn, each of which relates to a different number of channels, terminal bases, sizes and / or geometries, etc. What is crucial is that all of the electronic fuses have the basic functions of the described electronic fuses, have at least one terminal base and a housing, and the conceptual structure in the housing is designed as described above.

[0047] * * * * *

Claims

Patent claims Set (100) consisting of a plurality n electronic fuses (S1, S2, S3,..., Sn) for the controlled separation and connection of one or more electronic circuits ik or channels with one of the fuses (S1, S2, S3, ..., Sn), wherein each fuse (S1, S2, S3, ..., Sn) has a fuse housing (10) and a connection base (20) with connection contacts (E, A), wherein these have an input contact (E) and for each circuit ik or channel to be switched k output contacts (A1, A2, A3, ..., AK), which in terms of circuitry have at least one carrier structure (32) integrated in the respective fuse (S1, S2, S3, ..., Sn) equipped with electronic switching elements (31) with electrical conductors or conductor tracks, which are each connected in terms of circuitry to the input contact (E), and wherein ne N with n > 4 and kt N with k = 1 , 2 ,3 to n.Set (100) according to claim 1, characterized in that the connection contacts (E, A) are designed as plug contacts, solder contacts, or press-in contacts with a common mounting direction or extension direction. Set (100) according to claim 1, characterized in that the connection contacts (E, A) are designed as screw contacts with an opening (22) provided for screwing. to electrically connect them to a circuit i« by means of a screwable connecting means. Set (100) according to claim 3, characterized in that the connection contacts (E, A) provided for screwing are arranged or protrude on opposite sides of the electronic fuses (S1, S2, S3, ..., Sn). Set (100) according to claim 1, characterized in that the input contact (E) has a current carrying capacity which corresponds to the sum of the current carrying capacity of the output contacts (A1, A2, A3, ..., AK) or is at least 60 - 80% thereof. Set (100) according to claim 1 or 2, characterized in that the input contact (E) is geometrically designed in cross-section to be equal to or larger than the sum of the respective cross-sections of the output contacts (A1, A2, A3, ..., AK). Set (100) according to one of the preceding claims, characterized in that furthermore several or all electronic fuses (S1, S2, S3, ..., Sn) have a communication interface (50) having a number of signal contacts (51) in the region of the plug-in base or connection base. Set (100) according to one of the preceding claims, characterized in that the or all switching elements (31) of the electronic fuses (S1, S2, S3, ..., Sn) are individually adjustable in their disconnection and switching conditions, in particular programmable or adaptable via an integrated communication interface (50). Set (100) according to claim 8, characterized in that the or all switching elements (31) of the respective electronic fuses (S1, S2, S3, ..., Sn) can be individually activated, deactivated or changed even in the installed state during normal operation, regardless of whether a specific disconnection or switching condition has occurred in the vehicle electrical system. Set (100) according to one of the preceding claims, characterized in that the disconnection or switching condition of one, several or all electronic switching elements represents either a current threshold or a voltage threshold, wherein in particular a switch-off condition is provided such that the vehicle electrical system voltage remains stable and, in the event of an excessive voltage drop in a circuit or load circuit, the relevant switching element (31) is switched to its disconnection position.Set (100) according to one of the preceding claims, characterized in that the set comprises at least one, preferably several, of the electronic fuses (S1, S2, S3, ..., Sn) as multi-channel fuses with a corresponding number of output contacts (A1, A2, A3, ..., AK). Fuse box (200) having a plurality of interfaces, in particular connection bases, designed for connection to a selection of electronic fuses (S1, S2, S3, ..., Sn) selected from the set (100) of n electronic fuses (S1, S2, S3, ..., Sn) according to claims 1 to 11. Fuse box (200) according to claim 12, characterized in that the fuse box (200) is designed to accommodate a mixed configuration of electronic fuses (S1, S2, S3, ..., Sn) according to claims 1 to 11, as well as other fuse types, such as safety fuses and non-electronic fuses. Fuse box (200) according to claim 13, characterized in that the fuse box (200) is further designed with a plug-in base having contacts for inserting pluggable electronic modules (M1) and electronic assemblies with their mating contacts.

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