Multi-Voltage Cable With Intermediary Conductor
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Solution Overview
Problem
The conventional 12 V vehicle electrical system is inadequate in meeting the increasing demands for fuel efficiency, comfort, and reliability due to higher electrical consumer demands, leading to potential short circuits and electromagnetic compatibility issues with the introduction of higher voltage levels like 48 V.
Innovation Solution
A multi-voltage vehicle electrical system with at least three parallel flat cables and multiple voltage sources, where a separate flat cable serves as a ground return to minimize short circuits and improve electromagnetic compatibility, using materials like copper and aluminum for optimal heat dissipation and current-carrying capacity, and incorporating insulation and shielding for safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a higher voltage level (48 V) is introduced to improve power distribution efficiency, then the efficiency of power distribution is improved due to reduced current and ohmic losses, but the risk of short circuits and arcs between voltage levels increases
Solution Approach 1:
A potential equalizing connection (third flat conductor) is introduced between the voltage levels to act as an intermediary. This connection equalizes the potential between the 48V and 12V systems, preventing direct short circuits and arcs while allowing both voltage levels to coexist safely in the same cable assembly.
Solution Approach 2:
The cable assembly is segmented into multiple isolated flat conductors running parallel to each other, with distinct voltage levels separated by insulating material. This segmentation prevents electrical interaction between different voltage levels while maintaining organized power distribution.
2Power
If a higher voltage level (48 V) is introduced to supply high-power consumers, then the power supply capability is improved, but electromagnetic compatibility decreases due to increased electromagnetic coupling
Solution Approach 1:
Each flat conductor is assigned a specific voltage level and function (48V power, 12V power, or potential equalizing), creating localized electrical zones. The insulating material between conductors provides localized electrical isolation, reducing electromagnetic coupling while maintaining the power supply capability of the 48V system.
3Reliability
If separate power lines are routed for each voltage level, then the reliability of voltage level isolation is improved, but the device complexity and installation effort increase
Solution Approach 1:
Multiple flat conductors for different voltage levels (48V, 12V) and potential equalizing connections are merged into a single integrated cable assembly. The conductors run parallel and are isolated by insulating material within the same cable structure, maintaining voltage isolation while simplifying installation and reducing routing complexity.
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
This configuration reduces the likelihood of short circuits and arcing, enhances electromagnetic compatibility, and optimizes energy efficiency by allowing higher voltage levels to supply high-power consumers while maintaining reliability and safety.
Implementation Method 1
a third of the flat conductors is electrically connected to a second pole of the first and the second voltage sources... the third flat conductor is arranged between at least the first and the second flat conductor
Implementation Method 2
flat cables are significantly better suited for energy transmission than round cables due to their favorable surface-to-volume ratio and the associated improved heat dissipation
Data Source
Figure 1~4
Figure 5~7
Figure 8~10
AI summary
The invention relates to a multi-voltage onboard electric system for motor vehicles, comprising at least three flat lines (2a, b, c), which run substantially parallel to one another in their respective longitudinal directions, and at least two voltage sources (4, 6). A first flat line of the flat lines (2a) is connected to a first pole (4a) of a first voltage source of the voltage sources (4) in an electrically conductive manner; a second flat line of the flat lines (2b) is connected to a first pole (6a) of a second voltage source of the voltage sources (6) in an electrically conductive manner; and a third flat line of the flat lines (2c) arranged between the first and the second flat line is connected to a second pole (4b, 6b) of the first and/or second voltage source in an electrically conductive manner.