EV High-Voltage Distribution Module With Flexible Terminal Layout
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Solution Overview
Problem
Existing electrical power distribution systems in electric vehicles face challenges in efficiently managing high- and low-current devices, leading to improper vehicle operation and increased complexity and cost.
Innovation Solution
A power distribution system that integrates high- and low-current device terminals in a single enclosure, utilizing a power distribution unit (PDU) with customizable terminal placement and sensors to regulate power flow, including bus bars, ancillary expansion boards, and contactors to support various vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high- and low-current devices are housed in separate enclosures, then electrical isolation and safety are improved, but system size and cost increase
Solution Approach 1:
The patent combines high-current and low-current terminals within a single power distribution enclosure, eliminating the need for separate enclosures. The high-current terminals (for currents above 100A) and low-current terminals (for currents below 100A) are integrated in one housing with appropriate internal spacing and insulation, reducing overall system size while maintaining electrical isolation through design features such as insulated barriers and proper terminal placement.
2Ease of manufacture
If fixed terminal placement is used in the enclosure, then manufacturing simplicity is improved, but adaptability to different device arrangements deteriorates
Solution Approach 1:
The patent employs adjustable and reconfigurable terminal placements within the enclosure rather than fixed positions. The power distribution unit allows terminals to be positioned at various locations on the enclosure walls, enabling adaptation to different device arrangements and cable routing requirements while maintaining a standardized enclosure design for manufacturing efficiency.
3Reliability
If multiple separate power distribution units are used for high- and low-current devices, then functional specialization is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a universal power distribution unit that handles both high-current and low-current devices within a single enclosure. The unit incorporates terminal blocks and connection points that can accommodate different current levels, with internal routing and protection features that serve multiple functions. This multi-functional design reduces the number of separate components needed while maintaining appropriate electrical isolation and protection for different current types.
Data Source
AI summary
A power distribution system supplies electrical power to various parts of a vehicle. The system includes a power distribution board and ancillary expansion boards that regulate power distribution in the system. With this system, power can be routed to multiple high-current and low-current devices positioned in a variety of ways within the vehicle. The system includes high-current and low-current terminals that can be positioned in a variety of ways in the housing. The number of ancillary expansion boards in the system can be adjusted to supply power to a desired amount of low-current, ancillary devices on the vehicle. Further, one or more high-current terminals are configured to connect to a charger that sends power to the system.