Modular Vehicle Power Distributor Busbar Segmentation
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Solution Overview
Problem
Existing electrical power distributors for vehicles are complex in design and assembly, requiring soldering and multiple electrical connections, which increases manufacturing and assembly efforts.
Innovation Solution
A modular electrical power distributor with a base module and universal modules, where an electromechanical component like a relay or plug-in fuse bridges the structural separation of busbars, eliminating the need for soldering and reducing the number of electrical connections by using plug-in contacts and busbars with load contact elements that can be easily expanded according to vehicle configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical power distributors use soldered relays and multiple electrical connections, then reliable current distribution is achieved, but manufacturing and assembly complexity increases
Solution Approach 1:
The electrical power distributor is divided into modular components: a base module containing a first busbar and at least one universal module containing a second busbar. These modules can be independently manufactured and assembled, reducing overall assembly complexity while maintaining reliable current distribution through standardized connection interfaces.
Solution Approach 2:
An electromechanical component (relay or plug-in fuse) serves as an intermediary element that simultaneously establishes electrical contact between the first busbar and second busbar while providing switching or protection functions. This single component replaces multiple separate electrical connections and soldered joints, simplifying assembly while ensuring reliable current distribution.
2Reliability
If multiple electrical connections and soldering are used, then reliable electrical contact is achieved, but manufacturing effort increases
Solution Approach 1:
The electromechanical component integrates multiple functions into a single element: it provides electrical contact between busbars, enables current switching, and offers protection capabilities. This merging of functions reduces the number of separate manufacturing steps and electrical connections required, lowering manufacturing effort while maintaining reliable electrical contact.
Solution Approach 2:
The relay or plug-in fuse acts as an intermediary that establishes reliable electrical contact between the first and second busbars through its contact elements, eliminating the need for multiple separate soldered connections and reducing overall manufacturing complexity.
3Reliability
If relays are soldered into the power distributor, then stable electrical connection is achieved, but assembly time increases
Solution Approach 1:
The electromechanical component is designed as a plug-in unit that establishes electrical contact between busbars through its integrated contact elements, eliminating the time-consuming soldering process while maintaining stable electrical connections through mechanical contact forces and contact spring mechanisms.
4Ease of manufacture
If the power distributor is designed with fixed configuration, then production simplicity is maintained, but adaptability to different vehicle configurations decreases
Solution Approach 1:
The power distributor is segmented into a base module and universal modules that can be selectively combined in different configurations. This modular approach allows the same standardized components to be adapted to various vehicle electrical system requirements without complicating the production of individual modules, thereby maintaining production simplicity while enhancing adaptability.
Solution Approach 2:
The universal modules are designed with standardized interfaces and electromechanical components that can be applied across different vehicle configurations. This universality allows a single module design to serve multiple functions and adapt to various vehicle electrical system requirements, enhancing versatility without sacrificing production simplicity.
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
The solution simplifies the design and assembly of the power distributor, reducing manufacturing and assembly efforts while ensuring reliable current distribution and easy maintenance, as the electromechanical component can be easily plugged in and out, and diagnostic signals can be tapped directly from load contacts for state checking.
Implementation Method 1
an electromechanical component such as a relay for switching or a plug-in fuse of a (load) current fed into the first busbar contacts the first busbar with a first load contact and the second busbar with a second load contact
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an electrical power distributor (1) for a vehicle. This distributor has a base module (2) in which at least one first busbar (4) is arranged and electrically connected to a power supply unit (5) of the vehicle. The power distributor (1) also has at least one universal module (6) arranged adjacent to the base module (2), in which a second busbar (8) is arranged. According to the invention, a relay (11) for switching an electric current supplied to the first busbar (4) contacts the first busbar (4) with a first load contact (12) and the second busbar (8) with a second load contact (13).