Manual Service Disconnect for Battery Fuse Servicing
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Solution Overview
Problem
The existing battery systems require time-consuming and difficult servicing of low current fuses, which necessitates opening the battery pack casing and creating additional openings, compromising electrical shielding and increasing costs.
Innovation Solution
A manual service disconnect system with a disconnect header mounted externally to the battery pack, allowing for servicing of fuses without cutting additional openings in the casing, featuring a high current terminal connector, HVIL connector, and control device terminal connector, with a disconnect plug that exposes the current power control device for servicing and covers it when reconnected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If low current fuses are located inside the battery distribution unit inside the battery pack casing, then electrical shielding is maintained, but servicing of the fuses becomes time-consuming and difficult
Solution Approach 1:
The fuse system is segmented into two distinct locations: high current fuses are placed outside the battery pack casing in a battery distribution box for easy servicing, while low current fuses remain inside the battery distribution unit within the casing to maintain electrical shielding. This segmentation allows each type of fuse to be optimally positioned according to its specific requirements.
Solution Approach 2:
A battery distribution box serves as an intermediary component between the battery pack and the external environment. It houses the high current fuses and provides a convenient access point for fuse servicing without requiring opening of the battery pack casing, thus maintaining shielding while enabling easy maintenance.
2Ease of repair
If additional openings are cut in the outer casing to move low current fuses to the exterior, then fuse servicing becomes easier, but electrical shielding effectiveness is compromised and costs increase
Solution Approach 1:
The fuse system is segmented into two distinct locations: high current fuses are placed outside the battery pack casing in a battery distribution box for easy servicing, while low current fuses remain inside the battery distribution unit within the casing to maintain electrical shielding. This segmentation allows each type of fuse to be optimally positioned according to its specific requirements.
Solution Approach 2:
A battery distribution box serves as an intermediary component between the battery pack and the external environment. It houses the high current fuses and provides a convenient access point for fuse servicing without requiring opening of the battery pack casing, thus maintaining shielding while enabling easy maintenance.
3Ease of repair
If the whole battery distribution unit is removed to service low current fuses, then fuse replacement is possible, but service time and difficulty increase
Solution Approach 1:
The fuse system is segmented into two distinct locations: high current fuses are placed outside the battery pack casing in a battery distribution box for easy servicing, while low current fuses remain inside the battery distribution unit within the casing to maintain electrical shielding. This segmentation allows each type of fuse to be optimally positioned according to its specific requirements.
Solution Approach 2:
A battery distribution box serves as an intermediary component between the battery pack and the external environment. It houses the high current fuses and provides a convenient access point for fuse servicing without requiring opening of the battery pack casing, thus maintaining shielding while enabling easy maintenance.
Data Source
AI summary
A manual service disconnect for a battery system includes a disconnect header having a housing defining a receptacle, a high current terminal connector within the receptacle, a high voltage interlock (HVIL) connector within the receptacle and a control device terminal connector within the receptacle. A disconnect plug is removably coupled to the disconnect header. The disconnect plug has a high current fuse electrically connected to the high current terminal connector and a HVIL shunt terminal electrically connected to the HVIL connector. A current power control device is received in the receptacle and is electrically connected to the control device terminal connector. The current power control device is exposed for servicing when the disconnect plug is removed from the disconnect header and the current power control device is inaccessible when the disconnect plug is coupled to the disconnect header.