Eaton, a company specializing in intelligent power management, has recently announced that its eMobility business has secured a contract to supply its battery disconnect unit (BDU) to a renowned global vehicle manufacturer. This BDU will be utilized in both 400- and 800-volt configurations for electrified passenger vehicles. Eaton's BDU incorporates their advanced Breaktor® circuit protection technology, which effectively reduces complexity and cost in electric vehicles (EVs). The company plans to showcase this cutting-edge technology at The Battery Show in Stuttgart, Germany, from May 23-25, 2023. Additionally, on May 25, Eaton will lead a discussion on functional safety in electric vehicle systems during the conference.
Mark Schneider, the president of eMobility, expressed enthusiasm about collaborating with the world-class vehicle manufacturer, stating, "We are thrilled to provide this exceptional component of the EV system, equipped with industry-leading safety features and efficiency." Schneider further explained that Eaton's BDU integrates Breaktor® circuit protection technology, Bussmann™ fuses, and state-of-the-art Royal Power Solutions busbars. This integration ensures comprehensive electrical protection for the EV system within a compact and efficient package.
The primary function of the BDU is to act as an on/off switch for the vehicle's battery, depending on its operational mode, whether it be charging or driving. Presently, most EVs rely on one of three traditional circuit protection configurations within the BDU: fuse and contactor; pyro fuse and contactor; or a combination of fuse, pyro fuse, and contactor, all housed within a single BDU. Although each configuration offers switching and protection functions, they suffer from drawbacks such as increased system complexity, limited serviceability, coordination challenges, and vulnerability to fatigue under high current loads.
By integrating Breaktor® circuit protection technology into Eaton's BDU, additional functionalities and benefits are achieved. This includes the replacement of up to four high-voltage electrical components, reducing system complexity and overall costs. The device also offers both active and passive actuation in a single unit, as well as the ability to be reset after a high-energy fault. Altogether, Eaton's BDU eliminates the necessity for up to 15 additional system components.
To ensure a space-efficient design without the need for heat sinks, innovative busbars with a low-profile were implemented in the BDU. Eaton also utilizes an automated assembly process, resulting in enhanced safety, reduced production time, significant cost savings, minimal material waste, and rapid development of production-ready products. The power connections technology employed in the BDU was originally developed by Royal Power Solutions, which Eaton acquired in 2022. Additionally, Eaton's Bussmann™ series fuses were integrated to optimize BDU performance.
Schneider emphasized that with Breaktor and their Power Connections solutions, Eaton holds a unique position to deliver distinctive electrified vehicle solutions to its global clientele.
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