High Voltage Service Disconnect Assembly for EV Battery Modules
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Solution Overview
Problem
Existing high voltage service disconnect assemblies for electric vehicle battery modules lack the ability to safely create an open circuit, accommodate multiple fuse sizes, and prevent liquid ingress, leading to increased design costs and manufacturing complexity.
Innovation Solution
A high voltage service disconnect assembly comprising a first and second housing assembly with slidable fasteners and power tabs, allowing for adjustable fuse placement and sealing to prevent liquid entry, enabling safe operation and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a service disconnect assembly is designed to accommodate multiple fuse sizes, then adaptability is improved, but device complexity increases
Solution Approach 1:
The service disconnect assembly is designed with a universal mounting structure that can accommodate fuses of different sizes (e.g., 100A, 150A, 200A ratings) using the same housing and mounting mechanism. The fastener holders and power tabs are configured to accept various fuse configurations without requiring different assembly designs, thereby achieving multi-functionality while maintaining design simplicity.
2Reliability
If a service disconnect assembly creates an open circuit for safety, then reliability is improved, but device complexity increases
Solution Approach 1:
The service disconnect assembly is segmented into distinct functional components: a housing assembly containing the fuse and fastener holders, and a separate connector assembly with power tabs. This segmentation allows the open circuit function to be achieved through simple physical separation of the two assemblies, eliminating the need for complex switching mechanisms while maintaining safety reliability.
3Reliability
If a service disconnect assembly prevents liquid ingress, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The housing assembly incorporates a gasket or sealing element that creates a liquid-tight barrier between the fuse compartment and the external environment. This sealing approach provides reliable liquid ingress protection through a simple additive component rather than requiring complex sealed construction methods, thereby maintaining ease of manufacture while improving reliability.
Data Source
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AI summary
A high voltage service disconnect assembly is provided. The high voltage service disconnect assembly is configured to fixedly hold a plurality of different sized fuses therein having different current rating capabilities, one fuse at a time.