Fuel Cell Power Controller Layout for Compact Bus Bar Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fuel cell vehicles face challenges due to the bulkiness of fuel-cell DC/DC converters, which increases vehicle volume and complicates the arrangement of these components with junction boxes, affecting space utilization and energy transfer.
Innovation Solution
A fuel cell vehicle design that includes a junction box and a power controller with a fastening part to electrically connect them, allowing for improved space utilization and energy transfer, with the power controller positioned at the rear of the fuel cell and the junction box on top, using bus bars and screw parts for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a fuel-cell DC/DC converter is installed to boost the output voltage of the fuel cell, then the voltage requirement is met, but the vehicle volume increases due to the bulky converter
Solution Approach 1:
The patent merges the DC/DC converter function with the existing power controller by integrating the boosting circuit into the power controller's structure. This allows the voltage boosting function to be achieved without adding a separate bulky converter, thereby meeting the voltage requirement while avoiding increased vehicle volume.
Solution Approach 2:
The power controller is designed to perform multiple functions: it serves as both the power control unit and the DC/DC converter. By making the power controller multi-functional, the system eliminates the need for a dedicated boosting converter, thus achieving voltage boosting without increasing vehicle volume.
2Loss of energy
If the DC/DC converter is closely connected to the junction box for energy transfer, then energy transfer efficiency is improved, but the arrangement complexity increases
Solution Approach 1:
By integrating the DC/DC converter with the power controller, the patent reduces the number of separate components that need to be arranged and connected. The merged unit requires fewer connection points and simplifies the overall layout, thereby reducing arrangement complexity while maintaining close connection to the junction box for efficient energy transfer.
3Adaptability or versatility
If multiple separate components are used for voltage boosting and power control, then functional requirements are met, but the manufacturing cost and process complexity increase
Solution Approach 1:
The patent combines multiple functional components (DC/DC converter and power controller) into a single integrated unit. This reduction in component count directly simplifies the manufacturing process, reduces assembly steps, and lowers production costs while still meeting all necessary functional requirements for voltage boosting and power control.
Data Source
AI summary
A fuel cell vehicle is provided. The fuel cell vehicle includes a fuel cell, a junction box that is disposed on the fuel cell and includes a first bus bar, a power controller that is disposed at the rear side of the fuel cell and includes a second bus bar, and a fastening part that fastens the first bus bar and the second bus bar in a fastening space to electrically connect the junction box and the power controller to each other. One of the junction box and the power controller includes a tool inlet to allow access to the fastening space from the outside.