Removable Fuse Box Integration in EV Traction Powertrain Modules
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Solution Overview
Problem
Existing high-voltage modules in electrified vehicle traction powertrains require complex wiring and remote junction boxes for power distribution and fuse protection, making maintenance and upgrades cumbersome and inefficient.
Innovation Solution
A high-voltage module design featuring a removably insertable fuse box within an enclosure, providing power distribution and fuse protection, allowing for isolated access and replacement without disturbing the electronics assembly, and enabling interchangeable fuse configurations for enhanced serviceability and upgradability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a remote junction box is used for power distribution and fuse protection, then the electronics assembly can be protected, but the wiring becomes complex and maintenance becomes cumbersome
Solution Approach 1:
The fuse box is merged with the electronics assembly by being integrally formed with the enclosure and directly connected to the circuit board. This eliminates the need for separate remote junction boxes and complex wiring harnesses, while maintaining fuse protection functionality.
Solution Approach 2:
The fuse box is extracted as a separate removable module from the electronics assembly. This allows the fuse box to be independently accessed, removed, and replaced without disturbing the electronics assembly, simplifying maintenance while maintaining integration benefits.
2Device complexity
If the fuse box is integrated into the enclosure, then wiring is reduced, but access to fuses requires disturbing the electronics assembly
Solution Approach 1:
The fuse box is designed as a removable module that can be taken out from the enclosure without disturbing the electronics assembly. The socket provides a connection interface that allows the fuse box to be easily removed and replaced, enabling fuse access while maintaining integration benefits.
Solution Approach 2:
The fuse box is segmented as a separate functional module within the enclosure, with its own socket interface. This segmentation allows independent access to the fuse box while maintaining its integrated position when installed, resolving the conflict between wiring simplification and maintenance accessibility.
3Reliability
If the fuse box is permanently fixed, then connection reliability is improved, but upgrades and replacements become difficult
Solution Approach 1:
The fuse box connection is made dynamic through the removable socket interface. This allows the fuse box to be permanently secured during operation for reliable connection, while enabling easy removal and replacement for upgrades or repairs, providing both stability and flexibility.
Solution Approach 2:
The socket interface is pre-configured with alignment features and electrical contacts to ensure reliable connection when the fuse box is installed. This preliminary preparation allows for both secure operation and easy removal, facilitating future upgrades without requiring complex disassembly procedures.
Data Source
AI summary
A high-voltage module, such as a traction battery, a traction inverter, or a DC/DC converter of a traction powertrain of an electrified vehicle (EV), includes an enclosure and a fuse box. An electronics assembly for performing electrical power operations is housed within the enclosure. The enclosure has a socket. The fuse box is removably insertable into the socket of the enclosure. The fuse box connects to the electronics assembly while the fuse box is inserted into the socket of the enclosure for the fuse box to provide a power distribution and fuse protection arrangement to the electronics assembly.