PCB-Mounted Contactors and Shunts Without Wire Harnesses
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power distribution units for high voltage DC power are bulky, costly, and complex due to the use of wire harnesses for connecting contactors and shunts, which increases the risk of failure and complicates assembly.
Innovation Solution
Direct connection of contactors and shunts to a printed circuit board via pins eliminates wire harnesses, reducing mass, cost, and assembly complexity while enhancing reliability and interfacing with control circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If wire harnesses are used to connect contactors and shunts in conventional power distribution units, then electrical connections can be established, but mass, volume, cost, and assembly complexity increase
Solution Approach 1:
The patent extracts and eliminates the wire harness from the power distribution unit by implementing direct PCB mounting of contactors and shunts. This removes the intermediate connection element (wire harness) that added mass, volume, and assembly complexity while maintaining the essential electrical connection function through direct solder connections on the PCB.
Solution Approach 2:
The patent merges previously separate components (contactors, shunts, and wire harnesses) into a integrated PCB-mounted assembly. By combining these elements directly onto the PCB, the design reduces the number of discrete parts and simplifies the overall structure, eliminating the need for separate wire harness assembly.
2Volume of moving object
If wire harnesses are used to connect contactors and shunts, then electrical connections are provided, but space and cost increase
Solution Approach 1:
The wire harness is extracted from the system and replaced with direct PCB mounting. This eliminates the volume occupied by wire harnesses and their connectors, reducing overall space requirements while lowering material costs and manufacturing complexity.
Solution Approach 2:
The PCB serves multiple functions: it provides structural support, electrical connections, and mounting for contactors and shunts. This multi-functional approach eliminates the need for separate wire harnesses and reduces both space and manufacturing cost.
3Reliability
If wire harnesses are used for connecting components, then electrical connections are established, but reliability decreases due to more potential failure points
Solution Approach 1:
The wire harness is removed from the system, eliminating multiple potential failure points associated with wire connections, connectors, and routing. Direct PCB mounting reduces the number of interfaces and connection points, thereby improving overall system reliability.
Solution Approach 2:
By merging the electrical connection function directly into the PCB through solder joints, the design eliminates intermediate connection elements. This reduces the number of components and interfaces, lowering the probability of connection failures and improving reliability.
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 solution simplifies assembly, reduces space and weight, and provides more reliable connections, resulting in a more robust and cost-effective power distribution system.
Implementation Method 1
The pin receptacles can be solder connected to the circuitry of the circuit board
Data Source
AI summary
Power distribution units, such as for electric vehicles, having reduced mass, volume and complexity are achieved with a power distribution circuit board having pin receptacles for receiving and electrically connecting with corresponding pins, and contactors having pins located in fixed proximity to the circuit board to facilitate an electrical connection between a connector pin and a corresponding pin receptacle on the circuit board.