High-Voltage Power Distributor Assembly to Prevent Cable Rattle
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high voltage power cable splicing connections for automotive applications are prone to rattling and require manual assembly, lacking stability and robustness, and are costly.
Innovation Solution
A high voltage power distributor with a busbar connected to a non-insulated section of the cable, a fuse holder with a biased spring element, and a housing that stabilizes the assembly, eliminating the need for manual work and providing a robust, compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible connection between main power cables and fuse is used, then ease of assembly is improved, but stability and robustness deteriorate due to rattling and manual assembly requirements
Solution Approach 1:
The patent merges the fuse holder and cable connector into a single integrated housing unit. The fuse is directly mounted on the housing, and the cable is directly connected to the housing, eliminating the need for separate flexible connection elements. This integration ensures rigid, stable connections while maintaining ease of assembly through the unified structure.
2Reliability
If a complex splicing connection with multiple components is used, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The housing serves multiple functions simultaneously: it accommodates the fuse, provides the cable connection point, and structurally integrates these components. This multi-functionality reduces the total component count while maintaining robust connections, as the housing itself becomes the structural backbone for both the fuse mounting and cable attachment.
3Adaptability or versatility
If manual assembly work is required for splicing connections, then adaptability is improved, but productivity and assembly time deteriorate
Solution Approach 1:
The fuse and cable connector are pre-integrated into the housing structure during manufacturing. This preliminary integration means that during assembly, no manual splicing or complex connection work is required - the components are already positioned and structurally connected. The design enables automated or rapid manual assembly while maintaining adaptability through the modular housing design.
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 offers a stable, compact, and cost-effective splicing connection that minimizes assembly time and vibration, ensuring high pullout forces and a reliable power supply for auxiliary car equipment.
Implementation Method 1
at least one biased spring element is provided between the fuse holder and the housing to bias the fuse holder against the housing to exclude a relative movement between the fuse holder and the housing
Implementation Method 2
the busbar is welded to the cable, for example by means of ultrasonic welding
Data Source
Figure 1
Figure 2~5
AI summary
A high voltage power distributor comprises an insulated high voltage power cable, a fuse mechanically connected to a fuse holder and a busbar that is electrically connected between the cable and the fuse. The fuse, the fuse holder, the busbar and the cable are accommodated in a housing.