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Fuse Box Design & Mounting Chiho Wang Duke University

Fuse Box Design & Mounting Chiho Wang Duke University. HV granularity. Type 1: 14/module  6/module = 3/fuse box Type 2: 12/module  6/module = 3/fuse box Type 3: 10/module  10/module = 5/fuse/box Present design: type 1: 4 + 3 hv lines each box, no jumper

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Fuse Box Design & Mounting Chiho Wang Duke University

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  1. Fuse Box Design & Mounting Chiho Wang Duke University

  2. HV granularity • Type 1: 14/module  6/module = 3/fuse box • Type 2: 12/module  6/module = 3/fuse box • Type 3: 10/module  10/module = 5/fuse/box • Present design: • type 1: 4 + 3 hv lines each box, no jumper • type 2: 3+3 hv lines each box, no jumper • type 3: 2+3 hv lines each box, 1 jumper through 1 dummy connector contact • Possible new design options • type 1: 1+2 hv lines each box, no jumper • type 2: 2+1 hv lines each box, 1 jumper or 3+0 hv lines each box, 3 jumpers • type 3: 3+2 hv lines each box, 1 jumper (no change **)

  3. Design implications • Jumper: • wire  the 2 halves of a fuse box can not be separated. • Wire+sockets  2 halves separable but more mass & complexity • Symmetry: • Rotation symmetry for same side of fuse boxes (screw has to goes from outside to inside) • Mirror image symmetry for opposite side of module • If we can keep Rotation & Mirror symmetry on fuse box  Need only one type of fuse box for each type of module.

  4. Type 1 Current Distribution (0 jumper)

  5. Type 2 Current Distribution (1 external jumper, 2 internal jumpers)

  6. Type 2 Current Distribution (3 jumper)

  7. Type 3 Current Distribution (1 jumper)

  8. Dimension, Mounting, Grounding • Dimension: R x  x Z • Type 1 : 71 x 20.15 x 12 mm • Type 2 : 98 x 20.15 x 12 mm • Type 3 : 148 x 20.15 x 12 mm • Mounting: • 2 screw holes in inner half of fuse box • matching tapped stand from roof or cooling plate provide >2-3 turns of thread. (actual design ..??) • Nylon screw 2-56 • Grounding: • A ground wire with pin coming out from fuse box and plug into a socket on roof or cooling plate.

  9. Type 1 Dimension & Mounting

  10. Remaining design issues • Inside fuse box: • Lay out/Optimize circuit in fuse box • Locate mounting hole positions • Outside fuse box • Design of stand, including mounting orientation (can fuse box lay flat?) • Allocate (& reserve) mounting space/location • Grounding socket location in roof/cooling plate • Rotation symmetry on same side of module should be maintained to avoid complex wiring.

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