Modular Hybrid Power Distribution Unit for Vehicles
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Solution Overview
Problem
Current power distribution central units in vehicles lack modularity and flexibility, failing to effectively manage high power circuits and provide adequate electrical protection while minimizing circuit complexity and costs.
Innovation Solution
A hybrid power distribution central unit composed of modular components, including relays and fuses interconnected by stamped metal bars, allowing for customizable configurations and interchangeable modules with pre-fuses for high power circuit separation, optimized for reduced voltage drop and enhanced mass and space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional non-modular power distribution central units are used, then manufacturing and installation are simpler, but flexibility and adaptability to different vehicle configurations are reduced
Solution Approach 1:
The power distribution central unit is divided into multiple functional modules (power supply module, relay module, fuse module, load module) that can be independently configured and assembled. Each module handles specific functions, allowing the system to be customized for different vehicle applications without increasing overall system complexity.
Solution Approach 2:
The standardized interface and modular architecture enable the same module types to be used across different vehicle configurations and applications. The system can universally accommodate various power distribution requirements by simply reconfiguring which modules are present and how they are interconnected.
2Reliability
If high power circuits are not separately protected, then circuit protection is simpler, but electrical protection level and safety are reduced
Solution Approach 1:
Different protection mechanisms are applied to different circuit types based on their specific requirements. High power circuits receive dedicated pre-fuses and robust protection, while lower power circuits use standard fuses. This localized approach to protection ensures each circuit gets appropriate safety measures without over-engineering the entire system.
Solution Approach 2:
Pre-fuses are installed upstream in high power circuits before the main distribution points, providing preliminary protection before faults can propagate through the system. This proactive protection approach prevents catastrophic failures while maintaining clear circuit separation and management.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A hybrid power distribution central unit (1) is described, which comprises a housing (box) (2), provided with at least one cover (3) and internally defining a plurality of seats for coupling modules (12, 13, 14) of specific types, said housing (box) (2) comprising a power supply module (11) in order to electrically feed all the functional modules (12, 13, 14) coupled to the housing (box) (2). The functional modules are interchangeable according to their dimensions and not according to their specific types, thus, being possible for the hybrid power distribution central unit (1) to simultaneously use functional modules of different types.