Fuse Lock-Out Assembly Slidable Door Mechanism
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Solution Overview
Problem
Existing battery pack designs do not effectively prevent access to fuses when battery modules are electrically coupled within the pack, posing a risk of accidental voltage reduction or misuse.
Innovation Solution
A fuse lock-out assembly featuring a slidable door that covers the fuse compartment unless the manual service disconnect upper housing is de-coupled from the lower housing, ensuring fuses are inaccessible when the modules are coupled, and providing a fluid-tight seal when in the locked position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the slidable door is positioned to cover the fuse compartment, then fuse access is prevented, but the manual service disconnect upper housing cannot be removed
Solution Approach 1:
The slidable door is designed to be movable between two positions: covering the fuse compartment when the upper housing is installed, and moving away to allow housing removal. This dynamic element resolves the contradiction by changing its state based on the operational context.
Solution Approach 2:
The slidable door acts as an intermediary element between the fuse compartment and the upper housing. It provides the protective function when needed while being movable out of the way to allow housing removal, mediating between safety and accessibility requirements.
2Reliability
If the slidable door is made fixed to always cover the fuse compartment, then fuse access is always prevented, but maintenance and fuse replacement become impossible
Solution Approach 1:
The slidable door transitions from a fixed protective barrier to a movable access component. When maintenance is needed, the door can be slid open to allow fuse replacement, then closed again to restore protection. This dynamic behavior resolves the contradiction between permanent protection and maintenance accessibility.
Solution Approach 2:
The door assembly is segmented into a movable slidable portion and a fixed housing portion. This segmentation allows the protective function to be separated from the structural function, enabling the door to provide protection when closed while allowing access when opened for maintenance.
3Ease of operation
If the slidable door is positioned to allow housing removal, then ease of assembly is improved, but fuse compartment security is compromised
Solution Approach 1:
The slidable door dynamically adjusts its position based on whether the upper housing is being assembled or is in place. During assembly, the door moves away to allow housing installation, then automatically or manually returns to the closed position to restore security and prevent unauthorized access.
Solution Approach 2:
The slidable door is positioned in advance to facilitate housing assembly by being moved away from the fuse compartment. Once the housing is assembled, the door returns to its protective position, performing the security function before normal operation begins.
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
Prevents unauthorized access to fuses, ensuring operational voltage integrity and safety by only allowing access when the disconnect is de-coupled, thus maintaining voltage stability and safety.
Implementation Method 1
the slidable door has a gasket configured to contact a plate portion of the housing around the open end of the fuse compartment, when the slidable door is at the first operational position to provide a fluid-tight seal around the open end of the fuse compartment
Data Source
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AI summary
A fuse lock-out assembly for a battery pack is provided. The assembly includes a first housing having an interior region holding a manual service disconnect lower housing and a manual service disconnect upper housing therein. The assembly further includes a fuse holding housing coupled to the first housing that has a first fuse compartment holding a first fuse therein. The assembly further includes a slidable door that slides from a first operational position to a second operational position. The slidable door covers an open end of the first fuse compartment at the first operational position, and extends over a portion of the manual service disconnect lower housing at the second operational position only if the manual service disconnect upper housing is previously de-coupled from the lower housing.