Abstract
In this study, we designed and implemented a smart junction box (SJB) that was optimized for supplying power to low-voltage headlights (13.5 V) in electric vehicles. The design incorporated a number of automotive semiconductor devices, and components were placed in a high-density arrangement to reduce the overall size of the final design. The heat generated by the SJB was efficiently managed to mount an Intelligent Power Switch (IPS), which was used to power the headlights onto the printed circuit board (PCB) to minimize the impact on other components. The SJB was designed to provide power to the headlights via pulse width modulation to extend their lifetime. In addition, overload protection and fail/safe functions were implemented in the software to improve the stability of the system, and a controller area network (CAN) bus was provided for communications with various components in the SJB as well as with external controllers. The performance of the SJB was validated via a load operation test to assess the short circuit and overload protection functions, and the output duty cycle was evaluated across a range of input voltages to ensure proper operation. Based on our results, the power supplied to the headlights was found to be uniform and stable.
Highlights
As automotive technology continues to evolve from mechanical to electronic systems, consumers have started demanding higher performance products that are safer and more convenient [1,2,3,4]
smart junction box (SJB) in in this this study study included included aa power power supply supply and and control control unit unit that that were were designed designed to to stabilize the current supplied to the headlights by controlling the duty cycle of the voltage based on stabilize the current supplied to the headlights by controlling the duty cycle of the voltage based on the the pulse-width modulation (PWM)
The increasing adoption of electric vehicles has highlighted the need for efficient methods for generating, distributing, and managing the electrical power required to drive low-voltage automotive electronic components
Summary
As automotive technology continues to evolve from mechanical to electronic systems, consumers have started demanding higher performance products that are safer and more convenient [1,2,3,4]. As the complexity of the wiring harnesses in vehicles increased with the addition of more components and joints, simple fuse relay boxes became increasingly inadequate as they require labor-intensive assembly. As most lamps and motors in a vehicle are controlled via pulse-width modulation (PWM) signaling and receive their operating current from the IPS, the IPS needs to support both PWM signaling and monitoring via an MCU for diagnostic purposes [19,20] These recent requirements and existing problems in JBs have led to the development of smart. Recent SJBs incorporate an MCU for monitoring and control purposes These advantages have enabled in-vehicle power distribution systems in internal combustion engine vehicles and electric vehicles (xEVs) to evolve from fuse/relay-based.
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