Fuse and Power Distribution Blocks

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.

Relevant Regulations

8.5 - Both leads must be mechanically constrained to the battery enclosure using a fuse block and cover.

Current Mounting

Where are the fuses in the battery box - (circled in red):

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.

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

PDFs:

Weld Studs

Note - weld studs possibly used to create distribution blocks similar to above.

LittleFuse Fuse Holders:

https://www.littelfuse.com/products/fuse-blocks-fuseholders-and-fuse-accessories/powrgard-fuse-blocks/lffb.aspx

https://www.littelfuse.com/products/fuse-blocks-fuseholders-and-fuse-accessories/powrgard-fuse-blocks/lscr.aspx

https://www.littelfuse.com/products/fuse-blocks-fuseholders-and-fuse-accessories/powrgard-fuse-blocks.aspx

Styles / Options (not specifically EV-related)

These are NOT applicable or should be used for an automotive application due to the high reliability required in the harsh environments - vibrations, and temperature. They are listed merely as references to see what is out there and what styles of designs we could build off of.