Integrated Pre-Charging Fuse Assembly for Compact HV Circuits
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Solution Overview
Problem
Existing high voltage circuits in new energy vehicles face challenges with large volumes and high costs due to separate pre-charging resistors and fuses, which occupy significant internal space and increase production costs.
Innovation Solution
A multifunctional fuse integrates a pre-charging resistor and a fuse element within a single unit, where the pre-charging resistor is wound around an inner housing and the fuse element is connected in series with the high voltage loop, providing both pre-charging protection and overcurrent/short circuit protection, reducing internal space and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate pre-charging resistor and fuse are used in high voltage circuit, then both pre-charging protection and overcurrent protection functions are achieved, but the device volume and production cost increase
Solution Approach 1:
The patent combines the pre-charging resistor and fuse into a single integrated multifunctional fuse assembly. The resistor element and fuse element are housed together in one housing with shared terminal connections, eliminating the need for separate mounting spaces and reducing overall device volume while maintaining both pre-charging protection and overcurrent protection functions.
Solution Approach 2:
The multifunctional fuse assembly serves multiple protective functions simultaneously - it acts as both a pre-charging resistor for controlled charging and a fuse for overcurrent protection. This multi-functional design allows a single device to replace what would traditionally require two separate components, thereby reducing volume without compromising reliability.
2Reliability
If separate pre-charging resistor and fuse are used in high voltage circuit, then both pre-charging protection and overcurrent protection functions are achieved, but the production cost increases
Solution Approach 1:
By integrating the resistor and fuse into a single manufacturable unit with shared housing and terminal structures, the patent reduces the total number of parts that need to be sourced, assembled, and tested. This consolidation streamlines the manufacturing process and reduces production costs despite maintaining dual protection functions.
3Volume of stationary object
If pre-charging resistor is wound around inner housing, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The resistor element is wound around the inner housing in a nested configuration, where the resistor physically encircles the housing structure. This nesting approach maximizes space utilization by using the housing itself as the core around which the resistor is formed, while the housing structure provides natural support and positioning, actually simplifying assembly compared to separate mounting brackets.
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 multifunctional fuse effectively reduces internal space and production costs while maintaining performance, offering both pre-charging and overcurrent/short circuit protection functions, enhancing flexibility and adaptability in compact vehicle layouts.
Implementation Method 1
a pre-charging resistor is a resistor that slowly charges high-voltage electrical components such as capacitors at the beginning of high-voltage power-on of the entire vehicle
Implementation Method 2
when each high voltage loop has short circuit and overcurrent faults, the current fuse is fused in time to cut off the loop
Implementation Method 3
the current fuse is fused in time to cut off the loop
Data Source
AI summary
The present disclosure provides a multifunctional fuse. The multifunctional fuse includes a fuse element, a pre-charging resistor, and an inner housing. The inner housing is provided with a receiving cavity, the fuse element is received in the receiving cavity, and the pre-charging resistor is wound around an outer side of the inner housing and is in contact with the inner housing. The multifunctional fuse of the present disclosure resolves problems of large volumes and high costs of a pre-charging resistor and a fuse in a high voltage circuit in the related art.