Replaceable LV Connector Adapter With Integrated Fuse Pins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional EV HV battery systems require replacement of the entire battery module when an integrated fuse on the FPC malfunctions, leading to high replacement costs.
Innovation Solution
A replaceable adapter with integrated fuse design that includes a plurality of connector pins, which act as fuses and break in response to current spikes, allowing the entire adapter to be replaced instead of the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integrated fuse is placed on the FPC in conventional HV battery systems, then the sampling circuit is protected against current spikes, but the entire battery module must be replaced when the fuse malfunctions, leading to high replacement costs
Solution Approach 1:
The fuse function is segmented from the battery module and relocated to a separate adapter assembly. The adapter contains multiple connector pins that can individually function as fuses, while the battery module itself remains intact and reusable. This segmentation allows the fuse to be replaced independently without replacing the entire battery module, resolving the contradiction between maintaining circuit protection and reducing repair costs.
Solution Approach 2:
An adapter assembly is introduced as an intermediary component between the battery module and the harness. This adapter serves as a mediator that provides the fuse function while being separately replaceable. The adapter housing contains connector pins that act as fuses, and when these fail, only the adapter needs replacement rather than the entire battery module, thus reducing repair costs while maintaining protection.
2Reliability
If an integrated fuse is placed on the FPC, then the sampling circuit is protected, but the replacement time increases due to the need to replace the entire battery module
Solution Approach 1:
The fuse function is segmented from the battery module and placed in a separate adapter. This allows the adapter to be quickly replaced without the time-consuming process of replacing the entire battery module. The segmentation enables independent replacement of the fuse-containing adapter, significantly reducing replacement time while maintaining sampling circuit protection.
Solution Approach 2:
The adapter assembly is designed as a disposable or easily replaceable component that contains the fuse function. When the connector pins acting as fuses fail, the entire adapter can be quickly swapped out as a single unit. This approach uses a simpler, shorter-lived component (the adapter) to protect the more critical and time-consuming-to-replace battery module, thereby reducing overall replacement time.
3Reliability
If the FPC includes an integrated fuse, then the sampling circuit is protected, but the FPC layout becomes more complex
Solution Approach 1:
The fuse function is extracted from the FPC and relocated to the adapter assembly. This extraction removes the complexity of integrating fuses into the FPC layout, allowing the FPC to maintain a simpler design. The adapter housing contains the connector pins that serve as fuses, separating the protection function from the circuit board layout and reducing overall system complexity.
Solution Approach 2:
The adapter acts as an intermediary that provides the fuse function without requiring integration into the FPC. This intermediary component simplifies the FPC layout by eliminating the need to incorporate fuse elements directly into the circuit board, while still providing the necessary protection for the sampling circuit through the adapter's connector pins.
Data Source
AI summary
Systems and methods for an adapter for a high voltage (HV) battery system of an electrified vehicle (EV) involve an adapter housing configured to physically interface between (i) a battery module-side low voltage (LV) connector and (ii) a cell monitoring circuit (CMC) harness-side LV connector and a plurality of connector pins disposed within the adapter housing and being configured to, at their first ends, electrically connect to the module-side LV connector, at their opposing second ends, electrically connect to the harness-side LV connector, and act as a fuse such that at least one of the plurality of connector pins breaks an electrical connection therethrough in response to a current spike. In response to a blown fuse malfunction, the adapter could be replaced by a new adapter having a new adapter housing with a new plurality of connector pins disposed therein.