Task List
- Need a proposed design for a simple fuse block. A fuse block mechanically constrains the terminals of the fuse to the battery box enclosure. - start with this and check in with Micah Black
- Deliverable → A 3D model of the proposed fuse block, along with details on the materials and manufacturing processes selected to make it
- Finalize and prototype battery fuse block
- Design the blocks for the Rear Electrical enclosure (there are many more fuses in this section
GrabCAD link for the battery box is here:
MSXIV → Development → Battery Box → CAD → Rev 6 → Rev 6 Assemblies → Battery Box
Why / What / Where?
There is 1 pair of conductors (high voltage (HV) and ground (GND)) exiting the battery pack, and multiple devices that need to connect to this high voltage connector:
Left Motor Controller
Right Motor Controller
Solar Enclosure (to solar sense boards)
Charger (Elcon charger output)
Pre-charge
DC-DC
These connections must all be fused according to regulation 8.5.B below.
So we need some way of splitting the 1 battery box output connector out to multiple connections with various sizes of wire gauge. This is the purpose of a power distribution unit, which typically incorporates all the fuses as well.
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8.5 - Both leads must be mechanically constrained to the battery enclosure using a fuse block and cover.
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Current Mounting
Where are the fuses in the battery box - (circled in red):
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Mounting
As you can see in this screenshot, the fuse is not currently mounted to anything, nor has any electrical connections (screenshot taken June 18, 2020) - we need to fix this. The examples below are mostly from the EV industry and are listed as design inspiration as a starting point.
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Styles / Options (specifically EV-HEV related)
Eaton Flex Power Distribution Unit
Chevy Bolt Power Distribution Unit
EBusbar Power Distribution Units
Huber and Suhner Power Distribution Units
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Note - weld studs possibly used to create distribution blocks similar to above.
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LittleFuse Fuse Holders:
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Styles / Options (not specifically EV-related)
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https://www.amazon.ca/Dual-Terminal-Stud-MRBF-Block/dp/B07L6RBY6S?th=1
https://www.mouser.ca/datasheet/2/87/a75820a5-77a5-41e8-9d8e-ece5546fdb8c-1623027.pdf
https://www.mouser.ca/ProductDetail/Bussmann-Eaton/C5268-2?qs=sGAEpiMZZMtRmoYvq3OwzLPstIWsKAJ%2FoS0DuQbWEkU%3D
LittleFuse Z Case
https://www.mouser.ca/datasheet/2/240/littelfuse-fuse-holder-zcase-smz-datasheet-1369637.pdf
Eaton Power Feed-Through block
https://www.digikey.ca/product-detail/en/eaton-bussmann-electrical-division/C7021-02N/283-4373-ND/2173686
LittleFuse Power Distribution Block
https://www.digikey.ca/product-detail/en/littelfuse-inc/LFD04013Z/F7158-ND/2839139
https://www.littelfuse.com/~/media/electrical/catalogs/powrgard-electrical-product-catalog.pdf
Eaton Power Distribution Block 2 terminal
https://www.digikey.ca/product-detail/en/eaton-bussmann-electrical-division/16021-2/283-3698-ND/1645047
http://www.cooperindustries.com/content/dam/public/bussmann/Electrical/Resources/product-datasheets-b/bus-ele-ds-10533-pdb-ul-recognized.pdf
Eaton Power Distribution Block Quick Connect
https://www.digikey.ca/product-detail/en/eaton-bussmann-electrical-division/11725-2/283-3685-ND/2173091
http://www1.cooperbussmann.com/pdf/40507fae-2635-4aa4-a19e-cea6fe063aae.pdf
