Integrated High-Voltage Contactor for Fewer Harness Failure Points
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Solution Overview
Problem
Conventional high voltage electrical systems, such as those in electric vehicles, face challenges due to the distribution of components like contactors, current sensing elements, fuses, and battery management systems, leading to increased complexity, cost, and potential failure points from wire harness connections.
Innovation Solution
An integrated contactor device that combines switching, fuse, battery management, and current measurement functionalities into a single unit, reducing the need for separate components and wire harnesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional distributed components (contactor, fuse, battery management system, current sensing elements) are used throughout the system, then each component can perform its specific function, but the system complexity, cost, and number of wire harness connections increase
Solution Approach 1:
The patent combines the contactor, fuse, battery management system, and current sensing elements into a single integrated device. This merging eliminates the need for multiple separate components and their associated wire harness connections, thereby reducing system complexity while maintaining comprehensive system protection functions.
Solution Approach 2:
The integrated device performs multiple functions simultaneously: it acts as a contactor for circuit control, a fuse for overcurrent protection, a battery management system for monitoring, and a current sensing element for measurement. This multi-functionality reduces the number of components needed while enhancing system protection capabilities.
2Reliability
If multiple separate components are used, then each component can be optimized for its specific function, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
By integrating multiple safety-critical functions into a single device, the patent simplifies the assembly process. The integrated device can be installed as one unit rather than requiring the assembly of multiple separate components, reducing assembly time and potential errors while maintaining high safety standards through built-in protection features.
3Adaptability or versatility
If distributed components with wire harness connections are used, then the system can be modular, but the number of potential failure points increases
Solution Approach 1:
The patent eliminates wire harness connections by integrating all necessary functions into a single device. This removes multiple potential connection failure points while maintaining the adaptability of the system through the integrated device's ability to perform multiple functions and interface with the electrical system.
4Reliability
If conventional separate components are used, then the system can meet basic functional requirements, but the cost increases due to multiple components and assembly
Solution Approach 1:
The integrated device consolidates multiple expensive separate components into a single unit, reducing the overall bill of materials cost. The integration also reduces assembly labor costs and simplifies testing procedures, while maintaining comprehensive system protection through the combined functions of contactor, fuse, battery management, and current sensing.
Solution Approach 2:
By designing a single device that performs multiple functions, the patent eliminates the need to purchase and install separate components for each function. This multi-functionality approach reduces total system cost while ensuring reliable system protection through integrated safety features.
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
The integrated contactor device simplifies assembly, reduces costs, enhances safety, and improves system protection by eliminating failure points, while meeting functional safety requirements and enabling higher current ratings.
Implementation Method 1
shunt-type current measuring devices, which typically utilize a shunt resistor and voltage measuring device in order to measure a current
Implementation Method 2
hall effect-type current measuring devices
Implementation Method 3
pyrotechnic fuse element (e.g., utilizing a combustion-driven plunger-type fuse element)
Data Source
AI summary
An improved contactor device includes a high voltage switching device, current sensing components, and battery management components that may include a disconnect device. The contactor device may integrate, e.g., into a single device, a number of functionalities conventionally distributed across a number of disparate components and/or facilitate additional functionalities.