In-line Fused Connector for EV Power Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High voltage connector systems in electric and hybrid electric vehicles face challenges in safely managing high voltage power, particularly during mating and unmating, and existing solutions for fuse placement within power distribution modules are inconvenient for replacement.
Innovation Solution
An in-line fused connector assembly that includes a fuse subassembly with a mating terminal and an interlock terminal, allowing for controlled high voltage power management and easy fuse replacement through a front-end opening, ensuring safe operation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuses are placed inside power distribution modules, then safety protection is provided, but accessibility for replacement becomes difficult
Solution Approach 1:
The fuse system is segmented into modular fuse units that can be independently removed and replaced. Each fuse unit is a separate component that can be accessed through the connector housing without opening the power distribution module, enabling easy maintenance while maintaining safety protection.
Solution Approach 2:
The fuse function is extracted from the power distribution module and relocated to the connector assembly. This allows the fuse to be accessed, removed, and replaced through the connector's front opening without needing to open the module cover or remove other components inside the module.
2Productivity
If high voltage power is active during connector mating/unmating, then power delivery is efficient, but damage to connector and components occurs
Solution Approach 1:
The interlock circuit is activated in advance before high voltage power is applied. The interlock contacts must be properly engaged and the circuit closed before the high voltage mating contacts are connected, ensuring safety protocols are established prior to power delivery.
Solution Approach 2:
The interlock circuit serves as an intermediary control system between the mechanical connector engagement and the high voltage power delivery. It acts as a mediator that must be satisfied (circuit closed) before allowing the high voltage power to be applied, preventing direct connection without safety verification.
3Reliability
If interlock circuit control is implemented, then safety is improved, but device complexity increases
Solution Approach 1:
The interlock circuit functionality is merged with the connector assembly itself. The interlock contacts are integrated into the connector housing and mate with corresponding contacts in the opposing connector, combining the safety control function with the power connection function in a single integrated component.
Solution Approach 2:
The connector assembly serves multiple functions: it provides mechanical connection for power delivery, incorporates fuse protection, and implements interlock circuit control for safety. This multi-functionality reduces the need for separate dedicated safety components, managing complexity through integration.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
An in-line fused connector (102) includes an outer housing (106) and a fuse subassembly (210) disposed in the outer housing. The fuse subassembly (210) includes a mating terminal (206) that is configured to engage a first conductive body of a power distribution module and an internal terminal coupled with a fused conductor that electrically couples with an electronic device. The mating terminal (206) and the internal terminal are shaped to receive a fuse (212) to electrically couple the mating terminal (206) and the internal terminal. Electric current that is supplied by the power distribution module is conveyed through the fuse subassembly (210) when the fuse subassembly receives the fuse (212) and the mating terminal (206) of the fuse subassembly (210) mates with the first conductive body of the power distribution module through an opening (200) in a front end (108) of the housing (106). The fuse (212) is removable from the fuse subassembly (210) through the front end.