Battery Disconnect Unit Bus Bar Integration
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Solution Overview
Problem
Existing battery electrical systems for hybrid vehicles are time-consuming to assemble and prone to errors due to individual distinct wires, requiring an improved battery disconnect unit that simplifies assembly and reduces errors.
Innovation Solution
A battery disconnect unit with a circuit board and bus bars, along with pre-charging and charging relays, and contactors controlled by a microprocessor, which selectively couples and disconnects the battery pack from the hybrid powertrain system, utilizing a base portion, cover portion, and connector terminal assemblies to streamline assembly and reduce errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual distinct wires are used to couple each component in the battery electrical system, then the system can be assembled with flexible wiring, but the assembly process becomes extremely time-consuming and prone to assembly errors
Solution Approach 1:
The patent combines multiple individual wires and connection points into a single integrated circuit board with pre-established electrical pathways. The circuit board integrates the battery disconnect switch, relays, and connection terminals into one unified component, eliminating the need for separate wiring of each component and significantly reducing assembly time and errors.
Solution Approach 2:
The circuit board is pre-assembled with all electrical connections, relays, and switches already in place before installation into the vehicle. This preliminary integration of electrical components onto the circuit board allows for rapid installation as a single unit, avoiding time-consuming on-site wiring operations.
2Reliability
If individual distinct wires are used to couple each component, then component flexibility is maintained, but assembly errors increase
Solution Approach 1:
The patent merges multiple separate wiring operations into a single integrated circuit board assembly. By consolidating the battery disconnect switch, relays, and connection terminals onto one board with pre-established electrical pathways, the system eliminates complex individual wiring while improving assembly accuracy and reducing errors.
3Productivity
If a circuit board with bus bars and integrated relays is used, then assembly time is reduced and errors are minimized, but the device complexity increases
Solution Approach 1:
The circuit board is manufactured with all electrical components (relays, switches, bus bars) pre-integrated and connected during the manufacturing process. This preliminary integration transfers complexity from the assembly phase to the manufacturing phase, allowing for rapid and error-free installation in the vehicle while maintaining high assembly efficiency.
Data Source
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AI summary
A battery disconnect unit for selectively coupling a battery pack to a load is provided. The unit includes a base portion that holds first and second contactors, a pre-charging relay, and a charging relay, thereon. The unit further includes a circuit board having first, second, third and fourth bus bars disposed thereon. The first and second bus bars are coupled to first and second terminals, respectively, of the first contactor. The first bus bar is further coupled to the battery pack, and the second bus bar is further coupled to the load. The third and fourth bus bars are coupled to third and fourth terminals, respectively, of the second contactor. The third bus bar is further coupled to the battery pack, and the fourth bus bar is further coupled to the load.