WO2024068701A1

WO2024068701A1 - Modular electronic fuses and fuse box

Info

Publication number: WO2024068701A1
Application number: PCT/EP2023/076649
Authority: WO
Inventors: Olaf Eichler; Frank Schneider
Original assignee: Fep Fahrzeugelektrik Pirna Gmbh & Co. Kg
Priority date: 2022-09-27
Filing date: 2023-09-27
Publication date: 2024-04-04
Also published as: DE102022124801A1

Abstract

The invention relates to an architecture of a set (100) consisting of a number n of electronic fuses (S1, S2, S3, ..., Sn) for controlled separation and connection of one or more electronic circuits ik or channels having one of the fuses (S1, S2, S3, ..., Sn), wherein each fuse (S1, S2, S3, ..., Sn) has a fuse housing (10) and a connection base (20) having connection contacts (E, A), wherein these have an input contact (E) and output contacts (A1, A2, A3, ..., AK) for each circuit ik or channel k to be switched, which output contacts have, in terms of circuitry, at least one carrier structure/printed circuit board (32) integrated in each fuse (S1, S2, S3, ..., Sn) and equipped with electronic switching elements (31) and are each connected, in terms of circuitry, to the input contact (E).

Description

Modular electronic fuses and fuse box

Description:

The invention relates to a flexibly adaptable architecture of a modular solution of electronic fuses (eFuse) for protecting electronic circuits, preferably in a vehicle electrical system, and to a fuse box which can be modularly equipped with such electronic fuses. In addition to vehicle applications and on-board electrical systems, the invention also relates to other electronic applications in which a variable number of circuits must be flexibly secured.

Various fuses are already known in the prior art to separate electrical circuits. Traditionally, fuses are still used. used, but they have many disadvantages and are each set to a specific and fixed switch-off condition, for example a maximum permissible current. If the permissible current is exceeded, the melting wire is melted and the fuse is no longer functional.

Especially in motor vehicles, electrical consumers are typically arranged in an on-board electrical system. When it comes to consumers, a distinction is made between safety-relevant consumers and non-safety-relevant consumers, such as QM consumers (QM: quality management). When operating the on-board electrical system, it is important that the energy supply is always secured and guaranteed, especially for safety-relevant consumers. In order to ensure the safety of the on-board electrical system, it is known to monitor the energy supply in the on-board electrical system and thus in the motor vehicle. Basically, there is a need to fulfill functional safety (ISO26262) anyway.

Fig. 1 of DE 102020213357 A1 shows a possible topology of an energy supply system, consisting of a basic electrical system, which includes an energy storage device with an associated battery sensor, as well as several consumers that are protected or controlled by an electronic load distributor. The electronic load distributor includes several switching devices, each of which controls or protects safety-relevant consumers in particular. The semiconductor switches function, for example, according to certain criteria, such as (overvoltage, (over)current, temperature, etc., as an electronic fuse in order to isolate the respective protected consumer from the energy supply in impermissible operating states. On another

Switching means of the electronic load distributor is another example Load distributor connected, through which other consumers are protected (for example via fuses) and specifically supplied with energy. These consumers can be, for example, lighting, windshield wipers or consumers that are used, for example, after a vehicle crash. Furthermore, the electronic load distributor includes a separating means to separate the electronic load distributor from the partial on-board electrical system.

However, the load distributor and the switching means have a fixed topology that is tailored to the on-board electrical system and this topology cannot be flexibly transferred to other on-board electrical systems. For a number of different vehicles, even from the same series from one manufacturer, a large number of load distributors and fuse boxes are required in order to be tailored to the respective vehicle configuration. This is disadvantageous and time-consuming.

A circuit for controlling different electrical consumers in a motor vehicle is known from DE 4329860 A1. The solution relates to a circuit arrangement for controlling different electrical consumers in a motor vehicle. The circuit arrangement is connected on the input side to a voltage source and to input switches and on the output side to the consumers to be controlled. Each consumer is assigned an individual semiconductor element which disconnects the associated consumer from the voltage source when a short circuit occurs at the semiconductor element output and which reconnects the associated consumer to the voltage source when the short circuit ends. A semiconductor element is also provided for controlling consumers which convert a relatively high electrical power in the motor vehicle, such as a passenger compartment heater. MOSFET transistors are used in particular as semiconductor components.

The switching elements and safety devices are also firmly in place here Circuit installed, so that variable adaptation to different on-board networks or requirements is not easily possible.

The publications DE 102005013440 A, JP 2007288356 and EP 1870978 A show further alternative, but also inflexible solutions, each of which is statically tailored to a specific application.

In addition to the basic need for more variability and flexibility, there is also a need to be able to adapt or modify a fuse box or fuse architecture, especially after it has been installed in an application or vehicle electrical system. It would also be desirable to be able to activate and deactivate certain consumers and devices without a specific shutdown condition occurring during use.

It is well known that vehicle configuration involves a lot of effort if the customer requires certain components in the vehicle that are intended as accessories or special equipment. On the one hand, the configuration cannot be changed later and, on the other hand, there are features that one may want to be able to activate depending on user behavior in the company, for example by paying a fee.

With the solutions known in the prior art, such flexible, variable and operationally adaptable solutions cannot be implemented in the desired manner.

It is therefore the object of the present invention to overcome the disadvantages present in the prior art and, in particular, to propose a cost-effective, occasionally adaptable and flexible solution with which a variety of applications, in particular security concepts, can be combined in one Vehicle electrical system can be implemented.

According to the invention, a set consisting of a plurality of n electronic fuses (S1, S2, S3, ..., Sn) is proposed for the controlled separation and connection of one or more electronic circuits or channels with one of the fuses, each fuse having a fuse housing and a Has connection base with connection contacts. According to the invention, these have exactly one or at least one input contact and, for each circuit or channel to be switched, corresponding k output contacts, which in terms of circuitry have at least one circuit board equipped with electrical switching elements (or a support structure which has conductive elements/conductor tracks) integrated into the respective fuse and which are each connected to the input contact in terms of circuitry, whereby the following conditions apply: n e w with n > 4 and k e N with k = 1, 2, 3 to n.

The number of n electronic fuses is advantageous in the order of 10 to 50, or at least greater than or equal to 4, since modularity can then be achieved in a particularly efficient manner. Modular concepts are known in the state of the art, but according to the present idea, the combination of modularity at the fuse level (modular electronic fuse with multiple channels) on the one hand and the additional modularity at the variant level (fuses of different designs) on the other hand allows a significantly higher number of solutions to be implemented according to the modular principle with a significantly smaller number of variants provided. Here, the multi-channel vanants themselves are already particularly versatile, since these solutions enable modularity in a subordinate hierarchy (at the fuse level) in addition to modularity in a first (higher-level) hierarchy. The concept of the present invention therefore consists in the optimization and realization of the following components:

- modular design of electronic fuses (1-way/ 2-way/ 4-way/ .../multiple channels),

- Modular system consisting of modular fuses and variants,

- Possibility of combining different performance classes of the known classes of plug-in fuses from typically 1 to 80A or screw-in fuses from typically 80 to 400A

- At the same time, the possibility of a flexible, adaptable and modular structure of electronic fuse boxes (ePDU/eHSB) with the combination of individual plug-in modules, variants and the combination of other electrical modules on a common circuit board.

In a further advantageous embodiment of the invention, it is provided that the connection contacts are designed as plug contacts, solder contacts or press-in contacts with a common mounting direction or extension direction. In this way, particularly easy-to-assemble and clearly arranged boxes can be created in which all fuses can be fixed in one mounting plane and can be mounted, for example, by plugging in plug contacts.

A further optional development of the invention provides that the connection contacts are designed with an opening for screwing in order to connect them electrically to a circuit by means of a screwable connection means. For example, busbars or busbar connections with a screw solution are conceivable. It is also advantageous if the connection contacts intended for screwing are arranged on opposite sides of the electrical fuses or protrude.

It is further advantageous if the or all switching elements of the electronic fuses (S1, S2, S3, ..., Sn) can be individually adjusted in their disconnection and switching conditions, in particular if they can be programmed or adapted via an integrated communication interface.

Another aspect of the present invention relates to the design of the connections. It is advantageous that the input contact has a current carrying capacity that corresponds to the sum of the current carrying capacities of the plug contacts or is at least 60 - 80% of the sum. In this way, for example, a channel can be switched off (load shedding) and the current flowing through the input contact can be divided between the remaining channels or only directed via a safety-relevant circuit, i.e. one channel (if there is a temporary higher current requirement there). This function can be required, for example, if a circuit needs to be supplied safely to ensure the stability of the vehicle's electrical system, but no current needs to flow in another circuit protected by the same fuse. This dynamic adaptability represents a particular advantage over conventional solutions.

One possible implementation provides that the input contact is geometrically designed with a cross-section equal to or larger than the sum of the respective cross-sections of the plug contacts that are defined as outputs.

It is also advantageous if the or all switching elements of the respective electronic fuses are in the intended condition even when installed. can be individually activated or deactivated to ensure appropriate operation, regardless of whether a specific disconnection or switching condition has occurred in the on-board electrical system.

Also advantageous is a solution in which the disconnection or switching condition of one, several or all electronic switching elements represent either a current threshold or a voltage threshold, in particular a switch-off condition being provided to ensure that the vehicle electrical system voltage remains stable and at one high voltage drop in a circuit or load circuit, the switching element in question is switched to its disconnected position.

A further aspect of the present invention relates to a fuse box designed or having a plurality of interfaces, in particular connection bases designed for connecting to a selection of electronic fuses selected or selectable from the set of electronic fuses as described above.

It is also advantageous if the fuse box is designed to accommodate a mix of electronic fuses and other conventional fuse types, such as fuses.

Other advantageous developments of the invention are characterized in the subclaims or are shown in more detail below together with the description of the preferred embodiment of the invention with reference to the figures.

Show it: Fig. 1 electronic fuse designed as a plug-in module 20 - 40 A, 1 -way (ie for one protection channel or circuit);

Fig. 2 electronic fuse designed as a plug-in module 20 - 40 A, 4-fold (i.e. for 4 protection channels or circuits);

Fig. 3 electronic fuse designed as a plug-in module 1 - 20 A, 4-fold (i.e. for 4 protection channels or circuits);

Fig. 4 electronic fuse designed as a screw module 40 - 400 A, 6-fold (i.e. for 6 protection channels or circuits) and

Fig. 5 shows a hybrid fuse box with a selection of the inventive set Sn of fuses.

The figures are exemplary schematic. The invention is described in more detail below with reference to the figures, with the same reference numbers in the figures indicating the same functional and/or structural features.

Figure 1 shows an electronic fuse S1 designed as a plug-in module for 20 - 40 A, 1-fold, ie to protect a circuit or channel that runs from the input E via a switching element 31 on the circuit board 30 to the output A1. This exemplary fuse S1, selected from the set 100 consisting of a large number of electronic fuses S1, S2, S3, ..., Sn for the controlled separation and connection of one or more electronic circuits or channels, also has a fuse housing 10 and a connection base 20 (socket base) with the two connection contacts E, A1. Furthermore, the fuse S1 has a communication interface 50 with several signal contacts 51 for data transmission and communication with the fuse S1. For this purpose, the fuse S1 has corresponding electronic components 33 which are arranged on the circuit board 32. As can also be seen in Figure 1, the contacts E, A1, 51 each have a plug-side contact end 34, which can be inserted into a corresponding contact socket 61 on a mating plug base 60. At the opposite end of the respective contacts E, A1, 51 there are circuit board-side contact ends 34 for contacting the circuit board 32. Corner-side bearing and holding means 22 are also provided on the connection base 20 for supporting and laterally holding the circuit board 32. Furthermore, contact bearing blocks 22 are provided on the side facing the circuit board 32, through which the respective circuit board-side contact ends 34 protrude or protrude.

As can also be clearly seen in Figure 1, the contact geometry on the plug-in side of the contacts E, A1, 51 is designed differently and the flat contacts E, A1 form pin contact sections, preferably pin contact sections with a round or square cross-section. In this respect, a fuse with an optimized contact design is also proposed.

The circuit board can be equipped on both sides thanks to the concept of corner-side bearing blocks 22. At the upper end of the corner-side bearing blocks 22 there are L-shaped corner angle sections as a stop for the circuit board 32.

In Figure 2, an electronic fuse S2 is designed as a plug-in module for 1 - 20 A, 4-way, i.e. for protecting four circuits. One of the contacts represents the input contact E. Furthermore, four output contacts A1, A2, A3, A4 are provided, which are provided for each circuit ik (ii, i2, is, 14) or channel k to be switched and are connected via two circuits. at least one circuit board 32 equipped with electronic switching elements 31 integrated in the fuse S2 is connected to the input contact E. Otherwise, the topology of the fuse S2 is similar to the topology of the fuse S1 from Figure 1.

3 shows a fuse similar to FIG. 2, but is configured for different current strengths. Otherwise, the reference numbers indicate the features already explained.

Figure 4 shows an alternative solution for an electronic fuse S4, the fuse concept (and thus the structure inside the fuse housing 10) of which is conceptually analogous to the fuses S1 to S3. The connection base(s) 20 are divided on both sides on the two opposite long sides and provided with the connection contacts E, A1 - A6, whereby the connection contacts E, A1 - A6 are designed as screw solutions and therefore form an opening 22 that is used for screwing. It can also be seen that the connection cross-section of the output contacts A1 and A2 to A6 is designed differently. The total current that is divided between all output contacts A1 to A6 via the input contact E can, for example, also be conducted only via the output contact A1, which has been configured to be sufficiently large for this purpose (analogous to the input contact E). Furthermore, the fuse S4 has a communication interface 50 with several signal contacts (not shown) for data transmission and communication of the fuse S1 with an external device, for example a control unit.

5 shows a hybrid fusebox 200, which was configured to equip it with a number of electronic fuses S2, S5, S6 (from set 100). In addition (but not mandatory), conventional plug-in bases for fuses 2 can also be provided be. Furthermore, an electronic module M1 is optionally designed to be pluggable and inserted into a corresponding plug-in base.

The fusebox 200 according to the invention can also be designed as a non-hybrid solution. Furthermore, the invention can be used analogously in distribution boxes or load distributors, EM boxes, back-up fuse boxes or main fuse boxes, so that the term fuse box in the sense of the invention is generally understood to mean a fuse box in which a number of different electronic fuses Sn are used.

The implementation of the invention is not limited to the preferred exemplary embodiments given above. Rather, a number of variants are conceivable, which make use of the solution presented even in fundamentally different designs. According to the concept of the invention, the set 100 is not limited to the variants shown, but can include a large number of other electronic fuses Sn, each of which relates to a different number of channels, connection bases, sizes and/or geometries, etc. It is crucial that all of the electronic fuses have the basic functions of the electronic fuses described, have at least a connection base and a housing and that the conceptual structure in the housing is designed as previously described.

* * * * *

Claims

Claims Set (100) consisting of a large number of electronic fuses (S1, S2, S3,..., Sn) for the controlled separation and connection of one or more electronic circuits or channels with one of the fuses (S1, S2, S3, ... , Sn), each fuse (S1, S2, S3, ... , Sn), a fuse housing (10) and a connection base (20) with connection contacts (E, A), which has an input contact (E ) and for each circuit ik or channel k to be switched have output contacts (A1, A2, A3, ..., AK), which in terms of circuitry have at least one integrated in the respective fuse (S1, S2, S3, ..., Sn). have a support structure (32) equipped with electronic switching elements (31) with electrical conductors or conductor tracks, which are each connected in terms of circuitry to the input contact (E) and where ne N with n > 4 and kt N with k = 1, 2, 3 to n .Set (100) according to claim 1, characterized in that the connection contacts (E, A) are designed as plug contacts, solder contacts or press-fit contacts with a common assembly direction or extension direction. Set (100) according to claim 1, characterized in that the connection contacts (E, A) are designed as screw contacts with an opening (22) provided for screwing to connect these electrically to a circuit i« using a screwable connecting means. Set (100) according to claim 3, characterized in that the connection contacts (E, A) intended for screwing are arranged or protrude on opposite sides of the electronic fuses (S1, S2, S3, ..., Sn). Set (100) according to claim 1, characterized in that the input contact (E) has a current-carrying capacity which corresponds to the sum of the current-carrying capacity of the output contacts (A1, A2, A3, ..., AK) or is at least 60 - 80% thereof . Set (100) according to claim 1 or 2, characterized in that the input contact (E) is geometrically designed to have the same or larger cross-section than the sum of the respective cross-sections of the output contacts (A1, A2, A3, ..., AK). Set (100) according to one of the preceding claims, characterized in that several or all electronic fuses (S1, S2, S3, ..., Sn) also have a communication interface (50) which has a number of signal contacts (51). Area of the plug-in base or connection base. Set (100) according to one of the preceding claims, characterized in that the or all switching elements (31) of the electronic fuses (S1, S2, S3, ..., Sn) can be individually adjusted in their separation and switching conditions, in particular via an integrated one Communication interface (50) is programmable or customizable. Set (100) according to claim 8, characterized in that the one or all switching elements (31) of the respective electronic fuses (S1, S2, S3, ..., Sn) also operate as intended when installed, regardless of whether one a certain disconnection or switching condition has occurred in the on-board electrical system, can be individually activated or deactivated or changed. Set (100) according to one of the preceding claims, characterized in that the disconnection or switching condition of one, several or all electronic switching elements represent either a current threshold or a voltage threshold, in particular a switch-off condition being provided such that the vehicle electrical system voltage remains stable and at If the voltage drop in a circuit or load circuit is too high, the switching element (31) in question is switched to its disconnected position. Set (100) according to one of the preceding claims, characterized in that the set has at least one, preferably several, of the electronic fuses (S1, S2, S3, ..., Sn) as multi-channel fuses with a corresponding number of output contacts (A1, A2, A3, ... , AK). Fuse box (200) having a plurality of interfaces, in particular connection bases designed for connecting to a selection of electronic fuses (S1, S2, S3, ..., Sn) selected from the set (100) of n electronic fuses (S1, S2, S3, ... , Sn) according to claims 1 to 11. Fuse box (200) according to claim 12, characterized in that the fuse box (200) is designed to have a mixed assembly of electronic fuses (S1, S2, S3, ..., Sn) according to claims 1 to 11 as well as other other fuse types, such as Fusible fuses 2 and non-electronic fuses. Fuse box (200) according to claim 13, characterized in that the fuse box (200) is further designed with a plug-in base having contacts in order to insert pluggable electronic modules (M1) and electronic assemblies with their mating contacts into it.