Integrated Fuse Housing for Safe High-Voltage Replacement
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Solution Overview
Problem
In vehicle electric devices, existing fuse systems require battery disassembly for replacement, leading to poor workability and safety issues, as high voltage is not effectively cut off when the relay is fused.
Innovation Solution
A fuse-integrated electronic component with a coupling mechanism that separates the outer housing from the power supply part, using a first and second coupling member to disconnect terminals and a fuse to cut off high voltage, allowing safe and efficient replacement of fuses without disassembling the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the battery is disassembled to replace the fuse, then the fuse can be replaced, but the workability is significantly deteriorated and time is lost
Solution Approach 1:
The battery assembly is segmented into modular components: the battery body and the fuse holder assembly. The fuse holder can be independently removed from the battery by detaching the coupling member, allowing fuse replacement without disassembling the entire battery. This modular segmentation enables maintenance of the fuse while preserving the integrity of the main battery unit.
Solution Approach 2:
The fuse holder assembly is extracted as a separate serviceable unit from the battery system. The coupling member allows the fuse holder to be detached and removed from the battery, enabling technicians to access and replace the fuse externally without opening or disassembling the battery casing. This extraction principle makes the fuse replacement process independent of the battery assembly process.
2Reliability
If the relay is fused, then the circuit is protected, but the high voltage is not cut off when the interlock terminal is disconnected, significantly deteriorating safety
Solution Approach 1:
The fuse holder assembly is merged with the interlock terminal assembly, creating an integrated safety unit. When the interlock terminal is disconnected or the relay fuses, this merged structure ensures that the high voltage circuit is automatically interrupted. The physical coupling between the fuse holder and interlock terminal means that failure of either component results in circuit protection, eliminating the safety gap where voltage remained active despite interlock disconnection.
Solution Approach 2:
The coupling member acts as an intermediary mechanical link between the fuse holder and the battery assembly. This intermediary structure transmits the disconnection action from the interlock terminal to the fuse holder, ensuring that when the interlock terminal is disconnected, the fuse holder is also disconnected from the high voltage circuit, thereby automatically cutting off power without requiring additional control mechanisms.
3Object-affected harmful factors
If the first coupling member is designed to be released during fuse replacement, then safety is improved by cutting off power, but the device complexity increases
Solution Approach 1:
The coupling member is designed with multi-functionality: it serves as both the mechanical connector between the fuse holder and battery, and as the safety interlock mechanism. The same coupling structure that enables modular assembly also provides the automatic power cutoff function when released. This universal design eliminates the need for separate safety mechanisms, reducing overall system complexity while maintaining safety functions.
Solution Approach 2:
The coupling member is designed to automatically release and cut off power when the fuse replacement process begins. The mechanism self-activates based on the physical action of removing the fuse holder, without requiring additional control systems, sensors, or external intervention. This self-service特性 allows the safety function to be integrated into the basic mechanical coupling structure, minimizing added complexity.
Data Source
AI summary
A fuse-integrated electronic component connected to a power supply part includes an outer housing fixed by a first coupling member in a state in which housings are engaged with each other to define an accommodation space and in which an extension part is disposed at one side thereof, an inner body installed in the accommodation space by a second coupling member to define a mounting space, a connector electrically connected to the outer housing so that the extension part is accommodated therein, and a fuse installed in the mounting space to cut off a high voltage output to the connector. The first coupling member is coupled and released between the outer housing and the power supply part so that the first coupling member is released in a state of being separated from the power supply part, to doubly cut off the power when the fuse is replaced.