High-Voltage Box Modular Layout for Easier Wiring Maintenance
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Solution Overview
Problem
The layout of electrical components in existing high-voltage boxes is chaotic due to the lack of effective zoning and modular design, leading to cumbersome maintenance and disassembly of numerous wire harnesses.
Innovation Solution
A high-voltage box design featuring a substrate with installation regions for electrical components, an adapter for connection to a battery management system, and a modular structure that facilitates quick plug connections and regular component arrangement, enhancing assembly and maintenance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire harnesses or copper bars are used to connect the battery management system to electrical components, then electrical connection is achieved, but the layout becomes chaotic and maintenance becomes cumbersome
Solution Approach 1:
The patent divides the high-voltage box into distinct functional zones: a first accommodating space for the battery management system and a second accommodating space for electrical components. This spatial segmentation organizes the chaotic layout by separating different functional elements into dedicated regions, improving both connection reliability and maintenance ease.
Solution Approach 2:
The patent introduces a substrate as an intermediary component that integrates multiple electrical components (contactors, fuses, relays) into a modular assembly. This substrate acts as a carrier that simplifies the connection architecture, reducing the complexity of wire harnesses while maintaining reliable electrical connections.
2Reliability
If numerous wire harnesses are used for connections, then electrical connectivity is established, but disassembly and maintenance require disassembling many components
Solution Approach 1:
The patent merges multiple electrical components (first high-voltage contactor, second high-voltage contactor, fuses, relays) onto a single substrate, creating an integrated modular assembly. This consolidation reduces the number of separate connection points and wire harnesses, making disassembly and maintenance significantly easier while preserving all necessary electrical connections.
Solution Approach 2:
The substrate is pre-configured with all necessary electrical components and connections before installation into the high-voltage box. This preliminary assembly allows the entire modular unit to be installed as a single component, reducing on-site disassembly and maintenance complexity.
3Adaptability or versatility
If electrical components are arranged without zoning, then space utilization is flexible, but component layout becomes chaotic
Solution Approach 1:
The high-voltage box is segmented into functionally distinct zones: a first accommodating space for the battery management system and a second accommodating space for electrical components on the substrate. This zoning creates an organized layout that reduces device complexity while maintaining space flexibility within each zone.
Data Source
AI summary
A high-voltage box and an energy storage system are provided. The high-voltage box includes a main body, a battery management system, and an electrical module. The battery management system and the electrical module are detachably installed in the main body. The battery management system and the electrical module are provided adjacent to each other and are connected. The electrical module includes a substrate and a plurality of electrical components. The substrate is provided with a plurality of installation regions for installing the electrical components. The substrate is further provided with an adapter with a plurality of interfaces for connection with the electrical components and an external battery system respectively.