Integrated Breaker Relay for Electric Vehicle Power Distribution
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Solution Overview
Problem
Electrical power distribution in mobile applications, such as electric vehicles, faces challenges due to highly variable loads, thermal and mechanical stresses on fuses, complex electrical systems, and limited space and weight constraints, leading to integration complexities and increased costs and downtime.
Innovation Solution
A power distribution unit (PDU) with a breaker/relay system that includes a fixed contact electrically coupled to a power bus, a moveable contact, and an armature, biased by a first biasing member, allowing or preventing power flow based on current thresholds and auxiliary commands, integrated with an arc suppression assembly and a precharge circuit for efficient power management and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate breakers and relays are used in mobile applications, then circuit protection and power distribution functions are provided, but device complexity and integration challenges increase
Solution Approach 1:
The patent combines a breaker and relay into a single integrated device. The breaker portion includes a trip unit and contacts for circuit protection, while the relay portion includes a coil and contacts for power distribution control. This integration eliminates the need for separate breakers and relays, reducing wiring complexity and installation requirements while maintaining both circuit protection and power distribution functions.
2Adaptability or versatility
If multiple separate components are used for power distribution, then functional requirements are met, but weight and space constraints are exacerbated
Solution Approach 1:
The integrated breaker-relay device consolidates multiple components into a single unit, reducing overall weight. The breaker housing contains both the breaker mechanism and relay mechanism, eliminating duplicate structural elements, mounting hardware, and wiring that would be required if separate breakers and relays were installed.
3Adaptability or versatility
If complex electrical systems with multiple components are used, then power distribution requirements are met, but system response variations and noise increase
Solution Approach 1:
The integrated design reduces the number of connection points and interfaces between components. The relay contacts are directly mounted on the breaker housing, eliminating intermediate wiring and connection points that could introduce noise, resistance variations, and response delays. This direct integration ensures more consistent and predictable system response.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides reliable and efficient power distribution, reduces component size and weight, enhances integration, and minimizes downtime by selectively managing power flow and preventing overheating, thus addressing the challenges of variable loads and complex systems in mobile applications.
Implementation Method 1
an armature, biased by a first biasing member, allowing or preventing power flow
Implementation Method 2
integrated with an arc suppression assembly
Data Source
AI summary
A mobile application including a motive power circuit including a power storage device and an electrical load electrically coupled through a power bus; a power distribution unit (PDU) electrically interposed between the power storage device and the electrical load; wherein the breaker/relay includes: a fixed contact electrically coupled to the power bus; a movable contact selectively electrically coupled to the fixed contact; an armature operationally coupled to the movable contact; a first biasing member biasing the armature into a position; a contact force spring operationally interposed between the armature and the movable contact, such that in response to the armature being in the second position, the contact force spring is at least partially compressed; and a means for adjusting an opening velocity of the moveable contact, wherein the opening velocity comprises an initial velocity of the moveable contact away from the fixed contact in response to a physical opening response.