High-Voltage Control Box Wiring for Pluggable CAN Terminal Resistors
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Solution Overview
Problem
Existing high-voltage control boxes require manual assembly and disassembly of terminal resistors, which is time-consuming and labor-intensive, and lack versatility in meeting varying usage requirements.
Innovation Solution
A high-voltage control box design that integrates a terminal resistor within the control box body, connected via a wiring assembly to external electrical connectors, allowing easy connection or disconnection without disassembling the box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal resistor is integrated inside the control box body and connected via wiring assembly to external electrical connectors, then the ease of operation is improved (no disassembly needed), but the device complexity increases (additional wiring assembly and connectors)
Solution Approach 1:
The terminal resistor connection system is segmented into independent components: the terminal resistor itself, the wiring assembly with wiring terminal unit, and external electrical connectors. This allows the terminal resistor to be connected or disconnected by simply plugging or unplugging connectors without disassembling the control box body, resolving the contradiction between ease of operation and device complexity.
Solution Approach 2:
The wiring assembly acts as an intermediary between the terminal resistor and the external electrical connectors. It provides a standardized interface (wiring terminal unit) that simplifies the connection process while managing the internal wiring complexity, allowing external connectors to be plugged in without requiring internal modifications.
2Reliability
If the terminal resistor is preset inside the control box body, then the reliability is improved (fewer external connections), but the adaptability worsens (cannot be easily modified for different usage requirements)
Solution Approach 1:
The terminal resistor connection configuration is made dynamic through the pluggable external electrical connectors. The system can be easily reconfigured by connecting or disconnecting the connectors, allowing adaptation to different usage requirements while maintaining reliable electrical connections through standardized wiring terminals.
Solution Approach 2:
The wiring assembly with wiring terminal unit provides a universal interface that can accommodate different external electrical connectors. This allows the same control box body to adapt to different usage scenarios (with or without terminal resistor) by simply changing the external connector configuration, enhancing versatility without compromising connection reliability.
3Manufacturing precision
If manual assembly and disassembly of terminal resistors is required, then the manufacturing precision can be maintained, but the productivity deteriorates (time-consuming and labor-intensive)
Solution Approach 1:
The wiring assembly and wiring terminal unit are pre-assembled and integrated into the control box body during manufacturing. This preliminary preparation allows terminal resistors to be quickly connected or disconnected by simply plugging in external electrical connectors, eliminating time-consuming manual wiring operations while maintaining precise electrical connections through pre-positioned terminals.
Data Source
AI summary
A high-voltage control box includes a control box body, a terminal resistor, and a wiring assembly. A CAN bus and a battery management unit are provided inside the control box body. The CAN bus includes a high wire and a low wire, which are connected to the battery management unit. The terminal resistor is provided inside the control box body. The wiring assembly is installed on a wall of the control box body, and is connected to the high wire, the low wire and the terminal resistor. The terminal resistor is disconnected from the high wire and/or the low wire, and the wiring assembly is configured to be connected with an external electrical connector to enable the terminal resistor to be electrically connected with the high wire and the low wire through the wiring assembly and the external electrical connector.