Modular Switch Box for Vehicle Power Supply Adaptability
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Solution Overview
Problem
The frequent changes in the configuration of vehicle power supply systems necessitate the manufacture of new switch boxes, leading to increased development time and manufacturing costs due to the varying number of switches required.
Innovation Solution
A modular switch box design featuring a first circuit board with bus bars and a first switch portion, allowing for the attachment of a second circuit board with additional bus bars and switch portions, enabling flexible configuration to support changes in switch count without requiring new designs or manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of switches is changed to accommodate configuration changes in the power supply system, then the adaptability of the switch box improves, but the manufacturing cost and development time increase due to the need to manufacture new switch boxes
Solution Approach 1:
The switch box is divided into a first circuit board with a first switch portion and a second circuit board with a second switch portion. The second circuit board can be selectively attached or detached from the first circuit board, allowing the switch box to be reconfigured for different numbers of switches without manufacturing entirely new units. This segmentation enables cost-effective adaptation to configuration changes.
Solution Approach 2:
The switch box configuration is made dynamic through the removable second circuit board. The second circuit board can be attached when two switch functions are needed and detached when only one switch function is needed, allowing the system to adapt to configuration changes without permanent structural modifications or new manufacturing.
2Adaptability or versatility
If new switch boxes are manufactured to accommodate changing switch requirements, then the switch box functionality adapts to new configurations, but the development time and man-hours increase
Solution Approach 1:
By segmenting the switch box into modular circuit boards, the invention eliminates the need for time-consuming new design and development cycles when configuration changes are needed. The pre-designed modular boards can be simply assembled or disassembled, reducing development time from months to minutes.
Solution Approach 2:
The first circuit board is designed to serve multiple functions: it can operate alone as a complete switch box with one switch, or it can serve as the base for a two-switch configuration when the second circuit board is attached. This universal design eliminates the need for multiple specialized designs, saving significant development time.
3Ease of manufacture
If the switch box design is fixed for a specific number of switches, then the manufacturing process is simplified, but the ability to support different power supply system configurations is reduced
Solution Approach 1:
The modular segmentation maintains manufacturing simplicity for each individual circuit board while enabling configuration flexibility through assembly. Each circuit board can be manufactured using standard processes, and the final configuration is achieved through simple attachment or detachment, preserving manufacturing ease while improving adaptability.
Solution Approach 2:
The second circuit board is designed to attach to and nest with the first circuit board, forming a compact integrated structure when both switches are needed. This nesting approach maintains a simple overall form factor while allowing flexible configuration, avoiding the need for complex manufacturing processes.
Data Source
AI summary
Provided is a switch box comprising: a first circuit board; a pair of bus bars provided to the first circuit board; and a first switch portion that is provided to the first circuit board and that opens and closes a circuit between the bus bars. A second circuit board can be attached to and detached from the first circuit board, and the second circuit board comprises: one bus bar; and a second switch portion that opens and closes a circuit between the one bus bar and the bus bar of the first circuit board.