Vehicle Main Switch With Dual Current Paths for Leakage Detection
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Solution Overview
Problem
The existing electrical systems in vehicles, particularly agricultural and construction machines, face challenges in safely managing high electrical voltages and currents, which can lead to risks of electrical shock and component damage due to the increased voltage used for power efficiency, necessitating a reliable main switch to interrupt energy flow safely.
Innovation Solution
A main switch with dual current paths, a control unit, and sensors to detect current deviations, actuating switches to prevent leakage and short circuits, and a precharging and discharge circuit to manage voltage peaks and residual energy, ensuring safe operation and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If 48V direct current is used for power supply to reduce weight and manufacturing costs, then weight and manufacturing costs are reduced, but the risk of electrical shock and component damage increases
Solution Approach 1:
A main switch is introduced as an intermediary device between the 48V power supply and the electrical components. This switch acts as a mediator that controls the flow of high-voltage current, allowing it to be disconnected when not needed, thereby eliminating the electrical shock risk while preserving the benefits of 48V operation.
Solution Approach 2:
The electrical system is segmented into controllable sections using the main switch. This divides the continuous high-voltage circuit into isolated segments, allowing the power supply to remain at 48V for efficiency while specific portions of the system can be safely isolated from the high voltage when not in use.
2Reliability
If a main switch is installed in the line between the generator and the unit to interrupt energy flow, then safety is improved, but device complexity increases
Solution Approach 1:
The main switch function is extracted as a separate, dedicated safety component rather than being integrated into existing components. This standalone switch provides clear safety functionality while maintaining simplicity in the overall system architecture through its straightforward on/off operation.
Solution Approach 2:
The main switch serves multiple functions: it provides safety by interrupting energy flow, simplifies installation through its modular design, and enables galvanic isolation. A single component thus addresses multiple requirements, reducing overall system complexity despite adding a safety mechanism.
3Reliability
If sensors and control units are added to detect current deviations and actuate switches, then reliability is improved, but device complexity increases
Solution Approach 1:
The sensor and control unit system operates autonomously to detect current deviations and automatically actuate the switch. This self-service mechanism provides enhanced reliability through automatic protection without requiring complex manual control systems or additional operators.
Solution Approach 2:
The sensor provides feedback on current conditions to the control unit, which then adjusts the switch state accordingly. This feedback loop creates a simple yet reliable control system that automatically responds to electrical anomalies, improving safety without requiring complex decision-making architecture.
Data Source
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AI summary
The invention relates to a main switch (12) of an electrical system (10) of a vehicle (2), in particular an agricultural machine, comprising a first main current path (30) into which a first switch (34) is integrated, and a second main current path (32). The main switch (12) includes a control unit (38), and a first current sensor (42) is associated with the first main current path (30) and a second current sensor (44) with the second main current path (32). The first switch (34) is actuated by the control unit (38) depending on a deviation of the electrical currents detected by the two current sensors (42, 44).