Blind-Mate HPDM and RESS Electrical Integration
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Solution Overview
Problem
In electric powertrains, the use of high-voltage cables and bulky electrical connectors between the rechargeable energy storage system (RESS) and the high-power distribution module (HPDM) occupies valuable packaging space and requires additional cabling for low-voltage control and sensing signals, complicating the electrical connections.
Innovation Solution
The system modifies the RESS and HPDM to use low-profile ring terminal connections and inline high-voltage connectors, allowing the HPDM enclosure to be plugged directly into the RESS enclosure, eliminating the need for high-voltage cables and low-voltage control signals, and includes a water seal to prevent ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage cables and high-profile electrical connectors are used between RESS and HPDM, then reliable electrical connection is achieved, but packaging space is occupied and device complexity increases
Solution Approach 1:
The patent combines multiple separate electrical connections (high-voltage power cables and low-voltage control/sensing cables) into a single integrated connector assembly. This merging eliminates the need for separate cable bundles and multiple connection points, thereby reducing packaging space while maintaining reliable electrical connections for both power and control functions.
Solution Approach 2:
The electrical connector is designed to perform multiple functions simultaneously: it carries high-voltage power transmission, low-voltage control signals, and sensing signals all through a single connection interface. This multi-functionality eliminates the need for separate dedicated connections for each function, optimizing packaging space without compromising connection reliability.
2Reliability
If high-voltage cables and bulky connectors are used, then electrical connection is established, but device complexity and cabling requirements increase
Solution Approach 1:
The patent integrates high-voltage power conductors, low-voltage control conductors, and sensing conductors into a single unified connector assembly. This consolidation reduces the number of separate cabling routes, connection points, and assembly steps, thereby simplifying the overall cabling system while maintaining reliable electrical connections.
Solution Approach 2:
The connector is designed as a modular assembly with distinct segments for high-voltage connections and low-voltage connections, allowing for organized internal arrangement and simplified assembly. This segmentation within integration helps manage complexity by providing clear functional zones within the unified connector structure.
Data Source
AI summary
A system includes a rechargeable energy storage system (RESS) having an enclosure, battery cells, contactors, a first pair of high-voltage interlock (HVIL) ports, and female blind-mate electrical sockets selectively connected to the battery cells via the contactors. The battery cells and contactors are within the RESS enclosure. The system includes a high-power distribution module (HPDM) having another enclosure, male blind-mate electrical pins, a second pair of HVIL ports engagable with the first pair, ring-terminal connections connected to the blind-mate electrical pins and connectable to high-current components, and HV280 electrical connectors electrically connected to one or more of the male blind-mate electrical pins. The male blind-mate electrical pins insert directly into and engage with the female blind-mate electrical sockets of the RESS enclosure. A vehicle includes the system, a transmission, and an electric machine.