Dual Relay Assembly for Vehicle Electrical Distribution Centers
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Solution Overview
Problem
Automotive wiring systems often require additional relay-controlled circuits that existing electrical distribution centers (EDCs) cannot accommodate without increasing the size or complexity of the EDC, leading to cost and reliability issues.
Innovation Solution
A dual relay assembly is packaged within a single relay package, incorporating a circuit board with conductive traces, two relays, and a fusible link, allowing for increased circuit control without enlarging the EDC, and featuring a replaceable fuse to reduce size and eliminate separate fuse holders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional relay connectors are added to the EDC, then the number of relay-controlled circuits is increased, but the size of the EDC increases
Solution Approach 1:
The patent combines multiple relay connectors into a single integrated relay assembly. The relay assembly includes a circuit board with multiple relays mounted on it, allowing multiple relay-controlled circuits to be accommodated within a single compact unit that replaces what would traditionally require multiple separate relay connectors in the EDC.
Solution Approach 2:
The relay assembly serves multiple functions within a single component. It provides multiple relay-controlled circuits, integrates fuse holders for circuit protection, and consolidates multiple electrical connections into one assembly, thereby increasing the adaptability of the EDC without requiring additional space for separate components.
2Adaptability or versatility
If relay connectors are added outside the EDC, then the number of relay-controlled circuits is increased, but the wiring system complexity and cost increase
Solution Approach 1:
The patent integrates multiple relay connectors and their associated wiring into a single relay assembly unit. This consolidation eliminates the need for separate wiring harnesses and individual connector installations, thereby reducing wiring system complexity and installation cost while maintaining the capability to control multiple circuits.
Solution Approach 2:
The relay assembly is designed as a modular unit that can be installed as a single component. The circuit board with multiple relays is pre-assembled and tested, allowing for simplified installation and reduced wiring complexity compared to installing multiple separate relay connectors throughout the vehicle.
3Adaptability or versatility
If the EDC is redesigned to include additional relay connectors, then the number of relay-controlled circuits is increased, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple relay connectors into a single relay assembly that can be manufactured as one integrated unit. This approach allows for economies of scale in manufacturing, as the circuit board with multiple relays can be produced using standardized PCB manufacturing processes, reducing per-unit costs compared to redesigning the entire EDC structure to accommodate multiple separate connectors.
4Adaptability or versatility
If hard wired connections are made for additional relay connectors, then the number of relay-controlled circuits is increased, but reliability decreases
Solution Approach 1:
The patent integrates multiple electrical connections into a single relay assembly with a unified circuit board. This consolidation reduces the number of separate hard-wired connections and potential connection points that could fail, thereby improving reliability while still providing multiple relay-controlled circuits through the integrated design.
Data Source
AI summary
A relay assembly configured for use in a vehicle electrical distribution center. The relay assembly includes a circuit board, a first and second relay disposed the circuit board and a plurality of terminals electrically coupled to the first and second relays. The relay assembly also includes removable fuses to protect the circuits controlled by the first and second relays against over-current conditions. In one embodiment, the relay assembly is packaged as a mini-ISO relay package.