Modular High Voltage Distribution Unit for Hybrid Vehicles
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Solution Overview
Problem
In battery-powered systems, such as hybrid and electric vehicles, the design of spatial locations for connectors and fuses is complex and costly, requiring individual customization, and maintenance is complicated due to the need for accessible fuses during device operation.
Innovation Solution
A modular power distribution arrangement that includes an incomer module, feeder modules, and a distribution unit configured for easy installation and expansion, allowing flexible connection of multiple devices to a battery, with bus bar structures and interlock connections for efficient power distribution and fuse accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual customization of spatial locations for connectors and fuses is performed during battery design, then the battery can be tailored to specific device requirements, but the design complexity and manufacturing cost increase significantly
Solution Approach 1:
The battery system is divided into modular components: battery modules with standardized connectors, and device modules with corresponding interfaces. This segmentation allows flexible reconfiguration for different applications without redesigning the entire system, thus improving adaptability while controlling design complexity through standardization.
Solution Approach 2:
The battery design incorporates universal connector types and standardized mounting patterns that can accommodate multiple device configurations. The same battery module can serve different devices by simply changing the connection arrangement, eliminating the need for individual customization and reducing design complexity.
2Reliability
If wiring is required within the battery housing for each connector, then electrical connections can be established, but the manufacturing complexity and cost of the battery unit increase
Solution Approach 1:
Multiple electrical connections are merged into a single integrated wiring harness that distributes power to all connectors. This consolidates numerous individual wiring operations into one manufacturing step, significantly reducing manufacturing complexity while maintaining reliable electrical connections through the harness's structured design.
Solution Approach 2:
A standardized wiring harness acts as an intermediary component between the battery modules and device connectors. This mediator handles all electrical connections through a single interface, simplifying the manufacturing process while ensuring reliable power distribution to multiple devices.
3Ease of operation
If package space is guaranteed on the surface of the battery casing for connections, then devices can be plugged in, but the battery design becomes more constrained and complex
Solution Approach 1:
Connection points are distributed across multiple surfaces and dimensions of the battery casing rather than concentrating all connections on a single face. This three-dimensional arrangement provides adequate accessibility for device connections while optimizing space utilization and reducing design constraints.
Solution Approach 2:
Different regions of the battery casing are designed with specific connection characteristics tailored to local requirements. High-connection areas have optimized surface space and mounting features, while other areas maintain structural integrity, allowing accessible connections without overall design complexity.
4Ease of repair
If accessible fuses are provided for each device, then fuse replacement can be performed, but the risk of fuse replacement attempts with devices still plugged in increases
Solution Approach 1:
The system incorporates interlock mechanisms that prevent fuse replacement operations unless the associated device is first disconnected. This preliminary protective action automatically blocks access to fuses when devices are plugged in, eliminating the safety risk while maintaining fuse accessibility when needed.
Solution Approach 2:
An interlock mechanism acts as an intermediary between the device connection state and fuse accessibility. This mediator monitors whether devices are plugged in and controls access to fuses accordingly, allowing easy repair when safe and preventing harmful actions when devices are connected.
Data Source
AI summary
A distribution unit has an incomer module disposed on the exterior of a battery casing and electrically connected to a battery housed within the casing, and a plurality of feeder modules electrically daisy-chained to the incomer module and configured to respectively distribute electrical power from the battery to a plurality of individual electrically powered devices.