Junction Box Controller Thermal Management
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Solution Overview
Problem
Conventional methods for cooling the circuit of electrified vehicles with junction boxes, such as limiting power or using heat absorption sheets, can lead to reduced vehicle performance, decreased fuel efficiency, and increased emissions, and are costly and complex.
Innovation Solution
A junction box controller that uses temperature sensors to control the switching on and off of positive and negative electrode charging relays to efficiently dissipate heat through bus bars and wiring materials with high heat dissipation performance, alternately extending the heat dissipation area to cool the circuits effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods (limiting power or using heat absorption sheets) are used, then the circuit temperature is reduced, but vehicle performance decreases and fuel efficiency worsens
Solution Approach 1:
The patent introduces charging relays as intermediary components that enable controlled current flow through bus bars during charging operations. These relays act as mediators between the power source and the circuit, allowing heat dissipation through the bus bar structure without directly limiting the vehicle's power output or performance.
Solution Approach 2:
The bus bar structure is given multiple functions: it serves as both a current conductor and a heat dissipation component. By utilizing the bus bar's inherent thermal conductivity and surface area, the system achieves cooling without adding dedicated heat absorption components, thus avoiding performance penalties.
2Temperature
If conventional cooling methods (limiting power or using heat absorption sheets) are used, then the circuit temperature is reduced, but fuel efficiency decreases and emissions increase
Solution Approach 1:
The charging relays serve as intermediaries that enable the bus bar to function as a heat sink during charging operations. This approach utilizes the existing electrical infrastructure for dual purposes (current conduction and heat dissipation) rather than introducing separate cooling systems that would consume additional energy and reduce fuel efficiency.
Solution Approach 2:
The system uses its own electrical components (bus bars and charging relays) to provide the cooling function. The bus bar's inherent thermal properties are exploited for heat dissipation, and the charging relays automatically control the current flow to maximize heat dissipation during charging, making the system self-sufficient without external cooling aids.
3Ease of operation
If charging relays are switched off during system start, then the circuit can operate, but heat dissipation is insufficient leading to temperature rise
Solution Approach 1:
The patent implements dynamic control of charging relays based on real-time temperature monitoring. The relays are switched on or off according to the detected temperature levels, creating a dynamic response that balances circuit operation needs with heat dissipation requirements. This adaptive approach allows the system to maintain operational ease while preventing temperature rise.
Solution Approach 2:
The system incorporates temperature detection and uses this feedback to control the switching state of charging relays. When temperature rises above thresholds, the relays are activated to increase heat dissipation; when temperature is acceptable, the relays remain off to maintain circuit operation. This closed-loop feedback mechanism resolves the contradiction between operational ease and temperature control.
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 solution rapidly and efficiently cools the circuits, preventing overheating and maintaining vehicle performance while avoiding the drawbacks of conventional methods, such as reduced acceleration and increased emissions.
Implementation Method 1
a temperature sensor that detects the temperature of the circuit for vehicle travel
Implementation Method 2
efficiently dissipate heat through bus bars and wiring materials with high heat dissipation performance
Data Source
AI summary
A junction box controller controls a junction box including a circuit for vehicle travel that supplies power from a battery for vehicle travel to an electrical component for vehicle travel and a charging circuit including a positive electrode charging relay and an negative electrode charging relay that are for use in coupling and decoupling the battery for vehicle travel to and from an external charging power source in a state in which the positive electrode charging relay and the negative electrode charging relay are coupled to the circuit for vehicle travel. The junction box controller includes a temperature sensor that detects a temperature of the circuit for vehicle travel, and a controller that, when the temperature of the circuit for vehicle travel reaches or exceeds a preset threshold, controls and switches on either one of the positive electrode charging relay and the negative electrode charging relay.