EV High-Voltage Module Fuse Box Layout for Non-Invasive Service
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Solution Overview
Problem
Existing high-voltage modules in electrified vehicle traction powertrains require complex and invasive procedures for fuse replacement and maintenance, which can compromise the integrity of the electronics assembly and increase maintenance costs.
Innovation Solution
A modular high-voltage module design with a secondary enclosure portion housing a power distribution and fuse protection arrangement, allowing for isolated access and replacement of fuses without disturbing the main electronics assembly, reducing complexity and improving serviceability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse box is integrated within the main enclosure portion with the electronics assembly, then the structural integrity and electromagnetic compatibility are improved, but the complexity and invasiveness of fuse replacement procedures increase
Solution Approach 1:
The enclosure is divided into two distinct portions: a main enclosure portion housing the electronics assembly and a secondary enclosure portion housing the fuse box. This segmentation allows the fuse box to be accessed independently through a separate access point, enabling fuse replacement without disturbing the main electronics assembly while maintaining the integrated structure for electromagnetic compatibility.
2Stability of the object's composition
If the fuse box is accessed through the main enclosure portion, then the structural integrity is maintained, but the maintenance time and complexity increase
Solution Approach 1:
A separate access point to the fuse box is created in advance during design, allowing maintenance personnel to directly access the fuse box without needing to open or disturb the main enclosure portion. This preliminary structural arrangement eliminates the time-consuming process of accessing the main enclosure for routine fuse replacements.
3Ease of repair
If a separate removable cover is used for the fuse box, then the ease of fuse replacement is improved, but the device complexity increases
Solution Approach 1:
The fuse box is extracted into a separate secondary enclosure portion with its own removable cover, independent of the main enclosure portion. This allows the cover to be removed and reattached as a simple maintenance operation without affecting the main electronics assembly or requiring complex disassembly procedures, balancing ease of repair with acceptable structural complexity.
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, an electronics assembly for performing electrical power operations, and a fuse box for providing a power distribution and fuse protection arrangement to the electronics assembly. The enclosure includes a main enclosure portion and a secondary enclosure portion integrated together. The electronics assembly is housed within the main enclosure portion and the fuse box is housed within the secondary enclosure portion.