Integrated High-Voltage Distribution Unit for Vehicle Energy Storage
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Solution Overview
Problem
Conventional traction energy storage systems for vehicles, particularly commercial vehicles, require high integration and assembly efforts, necessitating extensive wiring and multiple connections to the high-voltage distribution device and charging interface, making the installation process time-consuming.
Innovation Solution
An electrical energy storage device with an integrated high-voltage distribution unit, preassembled with a battery contactor box and direct current charging interface, reduces cabling and eliminates the need for multiple plugs by incorporating a DC charging contactor and AC/DC converter within the housing, allowing for faster assembly and modular expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional traction energy storage systems are used with separate battery contactor box and high-voltage distribution device, then functional reliability is improved, but assembly complexity and installation time increase significantly
Solution Approach 1:
The patent combines the battery contactor box and high-voltage distribution device into a single integrated housing. The contactor box (4) and distribution device (5) share a common housing structure, with the distribution device mounted inside the contactor box housing. This merging eliminates the need for separate mounting locations and reduces the number of external connections required during assembly.
Solution Approach 2:
The integrated housing serves multiple functions simultaneously: it provides structural enclosure for both the contactor box and distribution device, acts as a mounting structure for both components, and serves as the interface for high-voltage connections. The housing walls function as both protective enclosures and electrical isolation barriers, eliminating the need for separate protective structures.
2Ease of repair
If conventional separate mounting of battery contactor box and high-voltage distribution device is used, then component accessibility for maintenance is improved, but installation time and cabling effort increase
Solution Approach 1:
While integrated, the patent maintains functional segmentation between the contactor box (4) and distribution device (5) within the housing. The internal arrangement allows these components to be accessed and serviced separately through designated access points, while their physical integration reduces overall installation time. The modular internal structure enables maintenance personnel to work on one component without completely disassembling the entire assembly.
3Reliability
If extensive wiring and multiple plugs are used for connecting traction energy storage to high-voltage system, then connection reliability is improved, but manufacturing complexity and assembly effort increase
Solution Approach 1:
The high-voltage output connections from the distribution device are directly integrated with the housing structure. The housing walls themselves serve as connection interfaces, eliminating the need for separate plug-and-socket assemblies. This direct integration reduces the number of discrete electrical connections from multiple plugs to a simplified interface structure.
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
This integration significantly reduces installation time and complexity by minimizing cabling and plug requirements, enabling quicker setup of traction energy storage systems in vehicles while providing flexible charging options through direct current and alternating current interfaces.
Implementation Method 1
An electrical energy storage device with an integrated high-voltage distribution unit, preassembled with a battery contactor box and direct current charging interface, reduces cabling and eliminates the need for multiple plugs by incorporating a DC charging contactor and AC/DC converter within the housing
Data Source
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AI summary
The invention relates to an electrical energy storage device, in particular for hybrid, plug-in hybrid, fuel cell, and electric vehicles. The electrical energy storage device comprises a housing containing an electrical energy storage device and a battery contactor box. A high-voltage distribution device, configured for current and voltage distribution, is also arranged in the housing.