A high-voltage module, such as a traction battery, a traction inverter, or a DC/DC converter of a traction powertrain of an electrified vehicle (EV), includes an enclosure and a fuse box. An electronics assembly for performing electrical power operations is housed within the enclosure. The enclosure has a socket. The fuse box is removably insertable into the socket of the enclosure. The fuse box connects to the electronics assembly while the fuse box is inserted into the socket of the enclosure for the fuse box to provide a power distribution and fuse protection arrangement to the electronics assembly.

An electrical fuse maintenance system includes sensor adapted to measure the current flowing through a fuse element, the voltage on the fuse element, the temperature of the fuse element, and/or the temperature of an environment surrounding the fuse element, a controller configured to monitor the current, the voltage, the temperatures over a period of time while the fuse element is connected to an energized electrical power unit. Based on the monitored current, voltage and temperatures, the controller is adapted to estimate a service life remaining of the fuse element.

The present invention provides a fuse unit, which reduces the number of components of a bus bar and eliminates alignment of tuning fork terminals, and a method of manufacturing the fuse unit. Disclosed is a method of manufacturing a fuse unit, which includes a bus bar including a battery terminal, a fuse connection terminal, and an external connection terminal and is manufactured by integrating the bus bar and a resin covering body by insert molding. In this manufacturing method, the fuse connection terminal is constituted of an input side tuning fork terminal connected to the battery terminal and an output side tuning fork terminal connected to the external connection terminal, the input side tuning fork terminal and the output side tuning fork terminal are connected by a joining portion so as to face each other, the bus bar including the fuse connection terminal is integrated with the resin covering body by insert molding. After the insert molding, the joining portion is cut and removed through a cutting window of the resin covering body, which exposes the joining portion to the outside, and the input side tuning fork terminal and the output side tuning fork terminal are separated.

A straight bus bar includes an axial direction and having a rigid first portion with a first contact surface connectable to a first fuse, an axially spaced rigid second portion with a second contact surface connectable to a second fuse, and a connecting portion electrically connecting the first portion and the second portion. The connecting portion is a resilient compensation portion having at least two lateral recesses extending from opposite sides into the bus bar making the connecting portion elastically bendable to allow a relative axial movement of the first and second portions when an axial force is applied to the bus bar.

Provided is an electrical connection box that is equipped with a newly constructed dark current circuit connection/disconnection mechanism that can be used to change circuits of the dark current circuit connection/disconnection mechanism and improve versatility. A conduction member holder has a conduction member holding portion that extends spanning over a plurality of cavities that are provided in a case. A conduction member includes: a first conduction member that is connected to a connection terminal of a dark current circuit housed in one of the cavities; and a second conduction member that is connected simultaneously to the connection terminal of the dark current circuits housed in one of the cavities and a connection terminal of another circuit housed in another cavity. The first conduction member or the second conduction member that is selected according to a required circuit configuration is mounted in the conduction member holding portion.

The invention relates to a current distributor (3) for a vehicle, having an input (E) and a plurality of load channels (LK1, LK2, LKn) which connect the input (E) to a connected load (L1, L2, Ln) via a safety fuse (F1, F2, Fn) and a line (W1, W2, Wn) in each case, and to a protection system (1) for a vehicle having such a current distributor (3). In this case, a standby channel (EK1) connects the input (E) to the connected loads (L1, L2, Ln) via an electronic fuse (EF1), wherein an evaluation and control unit (10) checks the safety fuses (F1, F2, Fn) for functionality and switches on a semiconductor switch (T) of the electronic fuse (EF1) and forms a redundant current path between the input (E) and the connected loads (L1, L2, Ln) via the standby channel (EK1) if at least one of the safety fuses (F1, F2, Fn) is identified as having been tripped.

A battery pack includes one or more battery modules provided with a plurality of battery cells, a bus bar connected to a module terminal of each battery module to electrically connect the one or more battery modules, and connected to an external batter management system (BMS) of the battery pack, and a fuse box including a fuse connecting each module terminal to the bus bar, and a vibration detection element attached to the fuse box or the bus bar to detect vibration flowing into the fuse connected to each of the battery modules, and the vibration detection element is directly connected to a battery monitoring integrated circuit (BMIC) through terminals at both ends thereof.

A high-voltage module, such as a traction battery, a traction inverter, or a DC/DC converter of a traction powertrain of an electrified vehicle (EV), includes an enclosure and a fuse box. An electronics assembly for performing electrical power operations is housed within the enclosure. The enclosure has a socket. The fuse box is removably insertable into the socket of the enclosure. The fuse box connects to the electronics assembly while the fuse box is inserted into the socket of the enclosure for the fuse box to provide a power distribution and fuse protection arrangement to the electronics assembly.

A circuit device for a vehicle is arranged in a power supply path. In the circuit device, a first conductive pattern and a second conductive pattern are arranged on an insulating layer. The first conductive pattern and the second conductive pattern are connected to each other by a fuse (circuit element). A bus bar is arranged on the first conductive pattern. Therefore, when a current flows through a conductor constituted by the bus bar and the first conductive pattern, the amount of heat generated in the conductor is small.

A vehicle is disclosed for indicating when a fuse is blown in a vehicle fuse box. An example vehicle includes an electrical system, a fuse box comprising a door and an inner panel, covered in part with respective luminous materials and a plurality of fuses positioned inside the fuse box, coupled to the electrical system. Each fuse comprise an LED coupled between terminals of the fuse, and a lens configured to direct light from the LED toward the door and the inner panel.