Electrified Vehicle Electrical System Component Integration
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Solution Overview
Problem
Electrified vehicle powertrains face challenges in managing in-rush current during startup, which can damage components due to unregulated capacitance, and require complex electrical systems with numerous connections and large packaging spaces.
Innovation Solution
The integration of a contactor enclosure housing contactor contacts, a solid state power relay, and a positive temperature coefficient resistor within a bussed electrical center enclosure, along with a contactor electromagnet, to regulate and distribute electric current efficiently, reducing in-rush current and packaging requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical components are housed in separate enclosures, then each component can be independently maintained and replaced, but the overall system occupies more packaging space and requires more connections
Solution Approach 1:
The patent combines the contactor enclosure and relay enclosure into a single integrated housing that contains both the contactor contacts and the precharge relay assembly. This merging of previously separate enclosures reduces the total packaging volume while maintaining the functional independence of each component through internal segmentation and dedicated mounting areas within the unified structure.
2Ease of manufacture
If electrical components are housed in separate enclosures, then each component can be independently maintained and replaced, but the system requires more connections and increased assembly complexity
Solution Approach 1:
The integration of contactor and relay enclosures eliminates the need for inter-enclosure electrical connections, reducing the total number of connections required. The internal arrangement provides direct electrical pathways between components without requiring external wiring harnesses, thereby simplifying both assembly and maintenance procedures while preserving component independence.
3Reliability
If traditional electrical system configuration is used, then component functionality is maintained, but in-rush current damages components due to unregulated capacitance
Solution Approach 1:
The precharge relay is positioned and configured to activate before the main contactor closes, establishing a controlled charging path for the capacitor. This preliminary action charges the capacitor through the precharge relay's controlled resistance, preventing dangerous in-rush current when the main contactor subsequently closes, thereby protecting components while maintaining full functionality.
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 configuration effectively reduces in-rush current and minimizes packaging space by integrating key electrical components, thereby enhancing the reliability and efficiency of the electrical system while simplifying assembly and reducing connection complexity.
Implementation Method 1
a positive temperature coefficient resistor disposed within the contactor enclosure
Implementation Method 2
a contactor electromagnet disposed within the contactor enclosure
Data Source
AI summary
An electrified vehicle electrical system includes, among other things, a contactor enclosure, and contactor contacts housed within the contactor enclosure. A resistor is housed within the contactor enclosure or is housed within a relay enclosure outside the contactor enclosure.