Vehicle Power Distributor with Plug-in Electronics
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Solution Overview
Problem
Current power distributors in vehicles are complex and costly due to the integration of ESD-sensitive electronic components on printed circuit boards, requiring costly handling and large installation spaces, and existing modular designs lack efficient control electronics integration.
Innovation Solution
A power distributor design featuring a central distributor module with a printed circuit board for electrical components and a separate electronic attachment with ESD-sensitive components, connected via plug-in contacts, allowing for reduced production times, lower costs, and higher power density, with auxiliary modules and fork contacts for easy adaptation and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ESD-sensitive electronic components are integrated on the printed circuit board, then control electronics integration is improved, but handling complexity and cost increase due to ESD sensitivity requirements
Solution Approach 1:
The power distributor is divided into two separate modules: a first module containing the printed circuit board with electrical components, and a second module containing the ESD-sensitive electronic components. This segmentation allows each module to be manufactured and handled independently, reducing overall complexity while maintaining integration capabilities.
Solution Approach 2:
The ESD-sensitive electronic components are extracted from the printed circuit board and placed in a separate second module. This extraction eliminates the need to treat the entire printed circuit board assembly as ESD-sensitive, simplifying handling procedures for the majority of components while still allowing electronic integration through the coupling interface.
2Adaptability or versatility
If ESD-sensitive electronic components are integrated on the printed circuit board, then control electronics integration is improved, but manufacturing cost increases due to ESD-sensitive handling requirements
Solution Approach 1:
By segmenting the power distributor into two modules, the manufacturing process can be optimized: the first module (printed circuit board) can be manufactured using standard processes, while the second module (electronic components) is manufactured separately with appropriate ESD precautions only where needed, reducing overall manufacturing costs.
Solution Approach 2:
Extracting ESD-sensitive components to a separate module allows the main printed circuit board assembly to be manufactured without expensive ESD-sensitive handling infrastructure, while the small second module can be manufactured with targeted ESD protection only during its specific assembly process.
3Adaptability or versatility
If plug receptacles are accommodated on the printed circuit board along with fuses, then electronic integration is achieved, but the base surface area must be very large
Solution Approach 1:
The power distributor is segmented into two modules, each with its own base area. The first module contains the printed circuit board with electrical components, while the second module contains the plug receptacles and electronic components. This segmentation allows for more efficient space utilization and reduces the overall footprint compared to accommodating all components on a single large printed circuit board.
4Adaptability or versatility
If a modular design with auxiliary modules is used, then adaptability is improved, but control electronics integration becomes critical and complex
Solution Approach 1:
The modular design is segmented into a first module with electrical components and a second module with electronic components. This clear segmentation simplifies control electronics integration by providing a dedicated interface (coupling interface with electrical connections) between modules, making it easier to manage control signals compared to integrating electronics across multiple auxiliary modules.
Data Source
AI summary
The power distributor for vehicles according to the present disclosure includes at least the following components: an electronic attachment and a central distributor module with a printed circuit board for electrical components, a feed-in busbar to connect the printed circuit board to a feed-in terminal, and a cable directly connected to the power distributor. The electronic attachment accommodates the ESD-sensitive electronic components and serves to switch and where applicable to diagnose the electrical components on the printed circuit board and can be connected to the printed circuit board by a plug-in contact with several terminals. According to the present disclosure, the advantages of the printed circuit board for unbundling the signals to the various electrical components are combined with the advantages of a separate electronic attachment.