Vehicle Branch Box Segmentation for Universal Maintenance
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Solution Overview
Problem
Conventional power source systems for vehicles, particularly electric automobiles, require different sizes of distribution boxes for varying vehicle grades due to voltage differences, leading to increased complexity and part counts, and maintenance challenges.
Innovation Solution
The power source system divides the branch box into a first branch box for the travel system and a second branch box for the equipment system, with the second branch box being used commonly across different vehicle grades, and positions the branch circuit outside the battery box to reduce connection counts and allow for independent maintenance of electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the branch box is designed to accommodate high voltage (1000V) for high-end cars, then the travel system can operate at high voltage, but the size of the branch box and bus bars increases
Solution Approach 1:
The patent divides the branch box into two separate units: a first branch box for the travel system and a second branch box for the equipment system. This segmentation allows the high-voltage first branch box to be sized appropriately for power-intensive travel operations, while the second branch box can use standardized lower-voltage components, thereby reducing the overall volume and part count.
Solution Approach 2:
The second branch box designed for the equipment system is made universal and can be used in common across both high-end cars (with 1000V travel systems) and general cars (with 500V travel systems). This universality reduces the number of different parts needed and simplifies maintenance, as the same equipment system branch box can serve multiple vehicle configurations.
2Power
If different sized distribution boxes are prepared for different vehicle grades, then voltage requirements are met, but the number of parts increases
Solution Approach 1:
By segmenting the branch box into travel system and equipment system components, the patent enables the equipment system portion to be standardized across different vehicle grades. This reduces the number of unique parts needed, as the second branch box can be universally applied to both high-end and general cars.
Solution Approach 2:
The second branch box for the equipment system is designed as a universal component that can be used in common across different vehicle grades. This universality directly reduces the total number of parts by eliminating the need for grade-specific equipment distribution boxes.
3Volume of stationary object
If the branch circuit is integrated inside the battery box, then space is saved, but maintenance requires removing the entire battery box
Solution Approach 1:
The patent extracts the branch circuit from the battery box and positions it outside. This extraction allows the branch circuit to be accessed and maintained independently without removing the battery box, significantly improving ease of repair while the battery box retains its compact integrated design.
Solution Approach 2:
By separating the branch circuit into an independent external unit, the patent enables modular maintenance where only the branch circuit needs to be accessed for repairs, not the entire battery box. This segmentation improves maintainability without compromising the space efficiency of the battery box.
4Ease of repair
If the branch box is divided into separate units for travel and equipment systems, then maintenance becomes easier, but the number of connections increases
Solution Approach 1:
The patent merges the first and second branch boxes through a coupling circuit that electrically connects them. This merging reduces the number of external connections needed by providing an integrated electrical pathway between the travel system and equipment system branch boxes, thereby reducing complexity while maintaining the maintenance advantages of separation.
Data Source
AI summary
A vehicle including: a battery box inside of which a plurality of battery cells are provided, auxiliary equipment that can operate using electrical power, a travel system that can travel using electrical power, and a branch box that electrically connects the battery cells and the auxiliary equipment, and that electrically connects the battery cells and the travel system.