Modular High-Voltage Box Layout for Faster Electrical Maintenance
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Solution Overview
Problem
The layout of electrical components in existing high-voltage boxes is chaotic due to the lack of effective zoning and modular design, leading to cumbersome maintenance and disassembly of numerous wire harnesses.
Innovation Solution
A high-voltage box design that integrates electrical components onto a substrate with modular electrical modules, featuring quick plug connections and a battery management system, allowing for regular arrangement and easy assembly/disassembly, with temperature monitoring and heat management systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical components are installed using wire harnesses or copper bars without modular design, then the high-voltage box can accommodate various electrical components, but the layout becomes chaotic and maintenance becomes cumbersome
Solution Approach 1:
The patent divides the high-voltage box into multiple functional modules (power module, control module, precharge module) with dedicated installation regions. Each module is independently arranged on the substrate, transforming the chaotic layout into an organized modular structure that maintains component versatility while enabling easy maintenance through module-level replacement.
Solution Approach 2:
The patent introduces a substrate as an intermediary carrier that integrates multiple electrical components and wire harnesses. This substrate acts as a modular platform that can be detachably installed in the high-voltage box, simplifying maintenance by enabling replacement at the module level rather than individual component level.
2Reliability
If a large number of wire harnesses are used to connect electrical components, then comprehensive electrical connections can be achieved, but disassembly during maintenance becomes time-consuming and cumbersome
Solution Approach 1:
The patent segments the electrical connection system into modular units mounted on the substrate. Each electrical component is installed in a specific region on the substrate with dedicated connection interfaces, allowing maintenance personnel to disconnect and replace entire modules rather than tracing and disconnecting numerous individual wire harnesses, thereby significantly reducing maintenance time while preserving connection reliability.
Solution Approach 2:
The patent implements preliminary integration of wire harnesses and electrical components during the substrate assembly phase. Connection terminals are pre-positioned and wire harnesses are pre-routed on the substrate before the entire assembly is installed in the high-voltage box, eliminating the need for complex on-site wiring during maintenance operations.
3Adaptability or versatility
If electrical components are arranged without effective zoning, then the high-voltage box can accommodate all necessary components, but the arrangement becomes chaotic and wiring becomes complex
Solution Approach 1:
The patent applies segmentation by dividing the substrate into distinct functional regions (power component region, control component region, precharge component region) with clear spatial boundaries. Each region is optimized for specific component types and their associated wiring, creating an organized layout that reduces cross-region wiring complexity while accommodating all necessary components through systematic zoning.
Data Source
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AI summary
A high-voltage box (100) and an energy storage system (1000) are provided. The high-voltage box (100) includes a main body (1), a battery management system (3), and an electrical module (2). The battery management system (3) and the electrical module (2) are detachably installed in the main body (1). The battery management system (3) and the electrical module (2) are provided adjacent to each other and are connected. The electrical module (2) includes a substrate (21) and a plurality of electrical components (22). The substrate (21) is provided with a plurality of installation regions for installing the electrical components (22). The substrate (21) is further provided with an adapter (228) with a plurality of interfaces for connection with the electrical components (22) and an external battery system (4) respectively.