High-Voltage Battery Connector Interlock With Fuse-Door Keying
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Solution Overview
Problem
The maintenance of high-voltage battery packs in electric vehicles is complicated by the lack of standardized connections and fuses, leading to safety concerns and increased costs.
Innovation Solution
A high voltage connector system with a keying post and interlock mechanism, combined with a fuse block and electrical switch, ensures safe and reliable connections while accommodating voltages exceeding 400-600 VDC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standardized connections and fuses are implemented for high-voltage battery packs, then safety and reliability are improved, but device complexity increases
Solution Approach 1:
The patent combines the connector and fuse into a single integrated high-voltage connector assembly. The fuse is positioned within the connector housing, and the maintenance device simultaneously establishes both mechanical connection and electrical fuse connection in one operation, eliminating the need for separate fuse installation steps and reducing overall system complexity while maintaining safety
Solution Approach 2:
The fuse is pre-installed and integrated into the connector assembly before use. The connector is designed with pre-configured fuse holders and connection terminals that are ready for immediate engagement with the battery pack, eliminating the need for on-site fuse installation and ensuring safety protocols are already in place before maintenance begins
2Reliability
If standardized connections and fuses are implemented for high-voltage battery packs, then safety is improved, but maintenance cost increases
Solution Approach 1:
The high-voltage connector is designed as a universal interface that can connect to multiple different battery pack types and configurations. The standardized connector design with integrated fuse allows a single maintenance device to service various battery systems, reducing the need for multiple specialized tools and lowering overall maintenance costs while ensuring consistent safety standards across different applications
3Reliability
If a keying post with interlock mechanism is used, then connection safety is improved, but ease of operation deteriorates
Solution Approach 1:
The keying post and interlock mechanism are integrated into the connector assembly as a unified safety feature. The maintenance device's connector includes a keying post that must engage with a corresponding recess in the battery pack connector, and the interlock mechanism is built into the same housing, allowing the safety features to be incorporated without adding separate operational steps or significantly increasing complexity
Data Source
AI summary
A battery maintenance system for use in performing battery maintenance on a battery of an electric vehicle including a battery maintenance device and a high voltage connector configured to connect the battery maintenance device to the battery of the electric vehicle. When a fuse door is removed from a fuse block of the connector, a mechanical component in a first position blocks a keying post and prevents a first connector side from coupling with a second connector side of the connector When the fuse door is in place and covering an interior of the fuse block, the fuse door places the mechanical component into a second position to allow the keying post to mate with the second connector side and to activate an electric switch to connect voltages to the fuse block.