High-Voltage Distribution Box Open-Circuit Trigger for Crash Isolation
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Solution Overview
Problem
Current electric vehicles face challenges in promptly disconnecting the high-voltage loop during collisions, leading to potential electric shock hazards for occupants and emergency responders.
Innovation Solution
A high-voltage distribution box with an open circuit trigger system, comprising a distribution box housing, high-voltage connectors, a low-voltage connector, and an open circuit trigger, which disconnects the high-voltage loop upon receiving an initiation control signal from a collision sensor, using a trigger resistor and expansion component to rapidly disconnect the series connection of high-voltage connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the airbag module sends a power-off signal through network or hard wire to disconnect main relays, then the high-voltage system is powered down, but the disconnection may be delayed or fail if modules, circuits, or actuators fail
Solution Approach 1:
The patent extracts the critical disconnection function from the complex network-controlled relay system and places a dedicated open circuit trigger directly in series with the high-voltage loop. This separate, simple mechanical disconnection mechanism operates independently of the vehicle's control network, ensuring reliable high-voltage interruption even when electronic control systems fail.
Solution Approach 2:
The open circuit trigger acts as an intermediary component between the collision detection system and the high-voltage loop. It receives initiation signals from the collision initiation system and physically interrupts the high-voltage current flow, serving as a reliable intermediary that translates electronic collision detection into mechanical circuit interruption.
2Speed
If a network or hard wire control system is used to disconnect relays, then the high-voltage system can be powered down, but the response time may be insufficient during collision
Solution Approach 1:
The open circuit trigger is pre-positioned in series with the high-voltage loop during normal operation, maintaining readiness to interrupt current instantly. The trigger mechanism and its connection to the collision initiation system are pre-configured, allowing immediate disconnection upon collision detection without requiring signal routing or relay actuation delays.
3Loss of time
If the open circuit trigger is placed in series with high-voltage connectors, then immediate disconnection is achieved, but the device complexity increases
Solution Approach 1:
The open circuit trigger employs a simple, fail-safe design that prioritizes rapid disconnection over long-term operational complexity. The trigger mechanism is designed as a dedicated, single-purpose component that can be easily replaced, accepting increased device complexity as a trade-off for the critical safety function of immediate high-voltage interruption.
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
Immediate disconnection of the high-voltage loop upon collision, reducing the risk of electric shock and associated casualties, thereby enhancing safety for both vehicle occupants and emergency personnel.
Implementation Method 1
The trigger resistor is configured to, upon receipt of the initiation control signal, control the expansion component to swell and deform to enable the connecting pin to disconnect the connection between the first end of the open circuit trigger and the second end of the open circuit trigger.
Data Source
AI summary
A high-voltage distribution box having an open circuit trigger, a collision initiation system, and an electric vehicle include a distribution box housing, a first high-voltage connector, a second high-voltage connector, a low-voltage connector, and an open circuit trigger. The first high-voltage connector, the second high-voltage connector, and the low-voltage connector are provided on a surface of the distribution box housing, and the open circuit trigger is provided inside the distribution box housing. The first high-voltage connector and the second high-voltage connector are connected to a high-voltage loop of the electric automobile, and the first high-voltage connector and the second high-voltage connector are connected in series via the open circuit trigger. The low-voltage connector is connected to a control line of the electric automobile and configured to send an initiation control signal to the open circuit trigger at a moment of collision.