Common HV Junction Box for Fuel Cell and Battery Switching
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Solution Overview
Problem
The separate development and installation of fuel cell and HV battery systems in motor vehicles result in redundant switch-on/off boxes, increasing costs, weight, and complexity, due to their independent housings and control systems.
Innovation Solution
Integration of the HV battery and fuel cell systems into a common High Voltage Junction Box (HVJB) eliminates the need for separate switch-on/off boxes by using a shared unit for both energy sources, which includes an electromechanical switching element, semiconductor switches, and pyrotechnic disconnection mechanisms for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate switch-on/off boxes are used for fuel cell system and HV battery, then each system can be independently controlled and managed, but the vehicle weight increases and installation space is consumed
Solution Approach 1:
The patent combines the fuel cell switch-on/off box and HV battery switch-on/off box into a single integrated switch-on/off box. This merging eliminates redundant components while maintaining independent control capabilities through a unified control unit that manages both energy sources, thereby reducing vehicle weight and installation space without compromising system reliability
Solution Approach 2:
The integrated switch-on/off box is designed with multi-functional capability to handle both fuel cell and HV battery operations. The control unit within the single box can independently manage each energy source according to different operational requirements, providing universal control functionality that replaces the need for separate dedicated control boxes
2Reliability
If separate switch-on/off boxes are used for fuel cell system and HV battery, then each system has dedicated control, but development and manufacturing costs increase
Solution Approach 1:
By merging two separate switch-on/off boxes into one integrated unit, the patent reduces the total number of components that need to be manufactured, tested, and installed. This consolidation lowers development costs, manufacturing expenses, and assembly complexity while maintaining dedicated control pathways for each energy source through the unified control architecture
3Ease of repair
If separate housings are used for fuel cell and HV battery, then each system can be independently maintained, but system complexity increases
Solution Approach 1:
The integrated switch-on/off box employs segmentation by providing separate connection terminals and control pathways for the fuel cell system and HV battery system. This modular internal structure allows independent maintenance and troubleshooting of each energy source while presenting a unified external interface, thereby reducing system complexity without compromising maintenance independence
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
This integration reduces weight, space, and component duplication, lowers costs, simplifies the system, and enhances component utilization, while providing safer high-voltage management through a unified control and disconnection mechanism.
Implementation Method 1
The common switch-on/off unit comprises at least one electromechanical switching element, in particular a contactor
Implementation Method 2
the common switch-on/off unit comprises at least one pyrotechnic short-circuit element which is adapted to ignite in the event of an accident of the motor vehicle and to disconnect the at least one fuel cell and the at least one HV battery from said electric circuit
Data Source
AI summary
An electrical energy system containing fuel cells and a method for operating an electrical energy system for a motor vehicle are provided.