Power Distribution Apparatus with Mapping Board for Bus Integration
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Solution Overview
Problem
Current electric power distribution and control systems for vehicles lack integration with communication buses, particularly for machines with low production runs, as they are not economically viable to control components with high current draw and do not include printed circuit boards for effective electronic control.
Innovation Solution
An electric power distribution and control apparatus comprising conductive plates with contact pads and pins, integrated with a printed circuit board and a mapping circuit board, allowing connection to a communication bus for data communication and controlled output responses, using a processor to manage inputs and outputs, and featuring a header for connecting the main and mapping boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an electronic system with printed circuit board is integrated into the power distribution apparatus, then communication bus connectivity and electronic control capability are improved, but the ability to control high current draw components deteriorates
Solution Approach 1:
The system is segmented into two distinct parts: a low-current electronic control system (printed circuit board with processor) and a high-current power distribution system (conductive plates with contact pads). The electronic system handles communication bus connectivity and control logic, while the conductive plates handle high current power distribution. This segmentation allows each subsystem to optimize for its specific function without compromise.
Solution Approach 2:
Contact pins serve as intermediaries that physically and electrically connect the electronic system (printed circuit board) to the power distribution system (conductive plates). These pins enable the electronic controller to send control signals to relays and other components while being isolated from the high current paths, thus protecting the electronic system while maintaining control capability.
2Adaptability or versatility
If the power distribution apparatus is tailored to specific vehicle requirements with custom configurations, then adaptability is improved, but manufacturing cost increases for low production runs
Solution Approach 1:
The apparatus is divided into standardized modular components (conductive plates, mapping circuit boards, contact pins) that can be independently manufactured using standard processes. This modularity enables customization of the final configuration by assembling different combinations of standard parts, avoiding the need for expensive custom tooling while maintaining adaptability to specific vehicle requirements.
Solution Approach 2:
The conductive plates and mapping circuit boards are designed with universal interfaces and standardized contact patterns that can accommodate multiple configurations. A single standardized plate design can serve different functions by varying the arrangement of contact pads and traces, allowing the same manufacturing processes to produce adaptable solutions for different vehicle applications.
3Adaptability or versatility
If mapping circuit boards with multiple configurations are used, then versatility for different vehicles is improved, but the complexity of ensuring correct assembly increases
Solution Approach 1:
Each mapping circuit board configuration incorporates asymmetric features such as uniquely positioned contact pads, non-uniform trace patterns, or configuration-specific mechanical features that create a unique geometric fingerprint. This asymmetry ensures that each board can only be correctly assembled in one orientation and position, preventing incorrect assembly while maintaining versatility through multiple distinct configurations.
Solution Approach 2:
Different mapping circuit board configurations utilize distinct color coding schemes for contact pads, traces, or mechanical features. This visual differentiation provides an immediate, intuitive indication of the correct configuration and assembly orientation, reducing assembly complexity by making the correct configuration obvious without requiring complex mechanical interlocks or assembly procedures.
Data Source
AI summary
An electric power distribution and control apparatus has a stack of conductive plates each having a plurality of spaced contact pads and conductive traces connecting the contact pads to others of the pads. At least one of the plates has contact terminals for connection to electrical components for supply of electrical current. An array of contact pins pass through holes in the plates at a respective one of the contact pads such that the array of pins provides connection between selected contact pads of different selected conductive plates. An electronic system for connection to a communication bus is added to the above known system by providing a main circuit board having the electronic components thereon, a mapping circuit board having a plurality of contact pads thereon arranged for connection to respective ones of the array of pins and a header having a male pin array and a female socket array connecting the main printed circuit board and the mapping circuit board.