Integrated HV Junction Box Layout for Fuel Cell Assembly
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Solution Overview
Problem
Existing vehicle fuel cell systems face complex, bulky, and expensive designs with time-consuming assembly processes due to the need for multiple components and separate junction boxes for electrical energy distribution and conversion.
Innovation Solution
A vehicle fuel cell assembly integrating a high voltage junction box adjacent to the fuel cell stack, which includes a single converter for voltage conversion and simplified conductor routing, reducing components and enabling quick assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate junction boxes are used for electrical energy distribution and conversion, then functional reliability is improved, but device complexity increases and assembly time increases
Solution Approach 1:
The patent combines multiple separate junction boxes into a single integrated high voltage junction box that houses both the voltage converter and distribution functions. This merging approach maintains the functional reliability of separate components while reducing overall device complexity and the number of assembly steps required.
2Ease of manufacture
If multiple separate junction boxes are used, then functional separation is improved, but assembly time increases
Solution Approach 1:
The integrated high voltage junction box combines voltage conversion and electrical distribution functions into a single pre-assembled unit. This reduces assembly time by eliminating the need to install multiple separate junction boxes while maintaining functional separation through internal compartmentalization and distinct connection terminals.
3Device complexity
If a single integrated junction box is used, then device complexity is reduced, but functional separation decreases
Solution Approach 1:
The integrated high voltage junction box employs internal segmentation to separate voltage conversion and distribution functions. The converter and distribution terminals are positioned at opposite ends of the housing with dedicated connection points, maintaining functional separation while presenting a single integrated unit for installation.
4Reliability
If separate converters are provided for voltage conversion, then conversion reliability is improved, but the number of components increases
Solution Approach 1:
The voltage converter is integrated within the high voltage junction box housing, combining the conversion function with the distribution function. This reduces the total number of components and assembly steps while maintaining conversion reliability through proper electrical isolation and dedicated mounting provisions within the junction box.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated design reduces complexity, cost, and assembly time while providing efficient electrical power distribution suitable for heavy-duty vehicles with high current transfer capability.
Implementation Method 1
the converter is adapted for conversion of a voltage of the fuel cell stack to a voltage of the connection interface for electrical connection to the high voltage vehicle interface
Data Source
AI summary
A vehicle fuel cell assembly for a vehicle has a fuel cell stack, a high voltage junction box that comprises connection interfaces for electrical connection to a high voltage vehicle interface, the fuel cell stack and a plurality of high voltage consumers of the vehicle. The high voltage junction box is arranged adjacent the fuel cell stack.