EV Emergency Stop Switch Layout for High-Voltage Shutdown
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Solution Overview
Problem
There is a need for effective safety measures, particularly emergency stop switches, in electric vehicles to safely disable or shutdown the vehicle while it is moving and unmanned, especially in high voltage battery systems used in electric agricultural work vehicles.
Innovation Solution
The implementation of multiple emergency stop switches located at strategic positions on the electric vehicle, including front, side, and rear surfaces, which disconnect the battery pack from the power distribution unit, and a drive-by-wire system with a dedicated emergency stop switch to disable steering, braking, and acceleration functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If emergency stop switches are added at multiple locations on the electric vehicle, then safety and accessibility for shutdown are improved, but device complexity increases
Solution Approach 1:
The emergency stop system is segmented into multiple independent switches distributed at different locations (front surface, side corner portions, rear surface) of the vehicle. Each switch independently connects to the power distribution unit to disconnect the battery pack, providing redundant safety mechanisms without requiring complex interconnections between switches
Solution Approach 2:
The emergency stop switches serve multiple functions: they can be activated by persons on different sides of the moving vehicle, they work for both manned and unmanned operations, and they provide a universal shutdown mechanism for the entire vehicle system regardless of location
2Ease of operation
If emergency stop switches are located at multiple positions including front, side, and rear surfaces, then accessibility for persons outside the vehicle is improved, but ease of operation deteriorates due to distributed control points
Solution Approach 1:
Each emergency stop switch is locally optimized for its specific position on the vehicle. The front surface switch is accessible to persons approaching from the front, while side corner portion switches are positioned for persons on either side, and the rear surface switch serves persons at the back. Each location provides ergonomic access appropriate to that specific position
3Reliability
If the drive-by-wire system is disabled during emergency stop, then safety control is improved, but productivity is reduced due to loss of automated control
Solution Approach 1:
The emergency stop switch performs preliminary anti-action by preemptively disabling the drive-by-wire system before any unintended automated movement can occur. When activated, it immediately switches the DBW system from controlled operation to disabled state, preventing potential harmful automated actions before they can execute
Data Source
AI summary
An electric vehicle (EV) includes a battery pack, an electric motor, an inverter connected to the electric motor, a power distribution unit (PDU) connected to the battery pack and the inverter, and at least one EV emergency stop switch configured to disconnect the battery pack from the power distribution unit (PDU) when the at least one EV emergency stop switch is activated. The first EV emergency stop switch is located at a front surface of the EV.