Frame-Mounted Power Distribution Module for Low-Loss E-Drivetrains
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Solution Overview
Problem
There is a need for improved modules that enable the compact mounting of power electronics components on heavy and medium-duty utility vehicles, specifically to minimize resistance losses and facilitate the simultaneous coupling of multiple electric drivetrain control components, while also allowing for flexible placement to reduce frame rail length usage.
Innovation Solution
The development of a power distribution assembly that includes a housing with a cable junction, fuses, contactors, and a charging circuit, along with a mounting system featuring a frame rail interface, vibration isolators, and debris deflectors, allowing for efficient power distribution and protection of components from road debris, while minimizing frame rail length occupation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If power electronics components are mounted in a compact arrangement on heavy duty utility vehicles, then resistance losses are minimized and frame rail length usage is reduced, but the complexity of mounting and coupling multiple components simultaneously increases
Solution Approach 1:
The power distribution system is divided into separate modules: a power distribution unit housing containing fuses, contactors, and charging circuits; a separate cable junction; and a mounting system with frame rail interfaces. This segmentation allows each component to be optimized independently while reducing overall resistance losses through strategic placement near the e-axle and electric motor.
Solution Approach 2:
Multiple power electronics components are nested within the power distribution unit housing, with fuses, contactors, and charging circuits arranged in a compact configuration. The cable junction is integrated into the housing structure, creating a nested arrangement that minimizes frame rail length usage while maintaining compact mounting.
2Length of stationary object
If multiple electric drivetrain control components are coupled simultaneously in a compact arrangement, then frame rail length occupation is minimized, but the difficulty of coupling and mounting these components increases
Solution Approach 1:
The mounting system combines multiple coupling functions into a single integrated structure with frame rail interfaces that simultaneously secure the power distribution unit housing, cable junction, and associated components. This merging of mounting functions simplifies the coupling process while achieving compact arrangement on the frame rail.
Solution Approach 2:
The power distribution unit housing serves multiple functions: it contains and protects electrical components (fuses, contactors, charging circuits), provides structural mounting to the frame rail, and integrates the cable junction. This multi-functionality reduces the number of separate components that need to be coupled, easing manufacturing while minimizing frame rail length.
3Loss of energy
If power distribution components are placed adjacent to the e-axle and electric motor, then resistance losses are minimized, but the availability of mounting space and flexibility in placement is reduced
Solution Approach 1:
The mounting system incorporates adjustable frame rail interfaces that can accommodate different vehicle configurations and mounting locations. The power distribution unit housing and cable junction assembly can be positioned at optimal locations near the e-axle and electric motor while maintaining adaptability to various frame rail geometries and vehicle platforms through the flexible mounting design.
Data Source
AI summary
A power distribution assembly includes a mounting system and a power distribution unit. The mounting system has a frame rail interface disposed along lateral sides of the power distribution assembly. The power distribution unit has a housing and a cable junction disposed on an exterior of the housing. The housing has an upper portion coupled with the frame rail interface and a lower portion disposed below the mounting system. The power distribution unit has one or more fuses, a contactor, and a charge circuit disposed in the housing. The lower portion of the housing has an access panel accessible from beneath a vehicle to which the power distribution assembly is coupled. Such access may be gained by removing a debris deflector and the housing. The power distribution assembly can be electrically coupled with a battery assembly and a charge inlet assembly, which can be coupled to the battery assembly.