Fuel Cell Relay Assembly Integration in Stack Case
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Solution Overview
Problem
Conventional fuel cell structures face restrictions in arranging fastening members due to the presence of relays and high voltage components, leading to increased component count, complex assembly operations, and space inefficiencies.
Innovation Solution
The fuel cell design incorporates a relay assembly within the stack case, eliminating the need for relay components on end plates, integrating a resin plate with relays and a service plug, and using a service plug installation hole for external connection, thereby reducing component count and simplifying assembly while ensuring insulation and miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relays and high voltage components are arranged on end plates, then current blocking function is achieved, but arrangement freedom of fastening members is restricted
Solution Approach 1:
The relay assembly is extracted from the end plate structure and relocated to the stack case. This separation removes the conflict between relay placement and fastening member arrangement, allowing fastening members to be positioned freely on end plates without interfering with relay components.
Solution Approach 2:
The relay assembly is moved from the two-dimensional surface of the end plate to the three-dimensional interior space of the stack case. This dimensional transition resolves the spatial conflict by utilizing unused interior volume rather than competing for surface area.
2Reliability
If multiple components are directly fastened onto end plates, then current blocking function is achieved, but number of components and assembly complexity increase
Solution Approach 1:
Multiple components (relays, terminal base, electric leak detector) are merged into a single integrated relay assembly unit. This consolidation reduces the number of separate components that need to be individually fastened to the end plate, thereby simplifying the overall structure and reducing assembly complexity.
Solution Approach 2:
The relay assembly is pre-assembled as an integrated unit before installation. This preliminary assembly of multiple components into one module reduces the number of fastening operations required during final installation, simplifying the assembly process.
3Strength
If end plates are made of metal material, then structural strength is achieved, but insulation distance requirements increase
Solution Approach 1:
The relay assembly acts as an intermediary insulating structure between the metal end plates and high voltage components. By positioning the relay assembly within the stack case rather than directly on the end plate surface, adequate insulation distance is maintained while preserving the structural advantages of metal end plates.
4Ease of repair
If service plug holes and covers are provided in stack case, then maintenance access is achieved, but component count increases
Solution Approach 1:
The relay assembly is designed to integrate multiple functions including the service plug functionality. By combining these functions into a single multi-functional component, the need for separate holes and covers is eliminated, reducing the overall component count while maintaining maintenance accessibility.
Data Source
AI summary
Relays and the like are arranged so that any restriction is not imposed on a portion where a fastening member between end plates or the like is disposed. To realize this, a relay assembly is provided in a stack case. In this case, when the relay assembly is integrated with a service plug, cables between relays and the service plug can preferably be omitted. Moreover, the relay assembly includes a resin plate to which the relays and the service plug are attached, and these relays are electrically connected to the service plug via buses on the resin plate.