Modular Vehicle Power Distribution with Controller Packs
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Solution Overview
Problem
Current power distribution systems in vehicles lack flexibility, reliability, diagnostics, and manufacturability, as they are often custom-designed and inflexible, leading to high costs and difficulties in adapting to changing electronic requirements.
Innovation Solution
A modular power and information distribution system comprising a backbone module with plug packs, each equipped with a controller pack that selectively connects terminals based on information received through a communication link, allowing for plug-and-play functionality and easy expansion without requiring extensive re-engineering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-designed electronic power distribution modules are used to meet specific vehicle requirements, then the system can provide specific functionality, but the system becomes inflexible and costly to change when requirements evolve
Solution Approach 1:
The power distribution system is divided into modular units (power distribution modules) that can be independently designed, manufactured, and assembled. Each module contains standardized components (fuse holders, relay sockets, terminals) that can be configured in different arrangements to meet specific vehicle requirements without redesigning the entire system.
Solution Approach 2:
The patent implements universal mounting structures and standardized electrical connections that allow the same basic module design to serve multiple vehicle models and applications. The modules can be configured to provide different functionalities (power distribution, body control, lighting) using the same fundamental module architecture.
2Adaptability or versatility
If expandable block assemblies are used to provide flexible power distribution, then the system can be scaled for different vehicle models, but reliability and diagnostic capability are insufficient
Solution Approach 1:
The system uses modular power distribution modules that can be independently tested and replaced. Each module is a discrete unit with defined functionality, allowing for targeted diagnostics and replacement without affecting the entire power distribution system.
Solution Approach 2:
The patent incorporates diagnostic capability through standardized communication interfaces and monitoring systems that act as intermediaries between the power distribution modules and the vehicle's control systems. This enables remote monitoring, fault detection, and diagnostic information gathering without requiring physical inspection of each module.
3Reliability
If mounted fuse and relay power distribution modules are used to improve reliability, then manufacturing issues are overcome, but flexibility is limited as they are designed around a given vehicle
Solution Approach 1:
The power distribution modules are designed with universal mounting patterns, standardized terminal configurations, and interchangeable components that allow the same module design to be used across multiple vehicle models and configurations. This universality maintains manufacturing reliability through standardized production while enabling flexibility in system assembly and configuration.
4Ease of manufacture
If printed circuit board base power distribution modules are used to support expandable block assemblies, then optional mounting features are provided, but diagnostic and intelligence logic are not available
Solution Approach 1:
The patent combines the manufacturing advantages of standardized printed circuit board technology with additional diagnostic and intelligence capabilities. The PCB modules are integrated with microprocessors, sensors, and communication interfaces that provide diagnostic information, monitoring, and intelligent control functions while maintaining the manufacturing efficiency of PCB-based construction.
Data Source
AI summary
A vehicle having a power and information system including a vehicle structural member, an insulated power conductor, a communication link and a modular distribution system. The modular distribution system is attached to the vehicle structural member. The modular distribution system is coupled with the power conductor and with the communication link. The modular distribution system includes a backbone module having an electrical power connection and at least one plug pack. Each plug pack includes a first connector, a second connector and a controller pack. The first connector is connectable to the backbone module. The second connector has a plurality of terminals. The controller pack selectively electrically connects at least one of the plurality of terminals to the electrical power connection dependent upon information received by way of the communication link.