Fuses are designed for the requirements of electric cars

September 01, 2016 // By Christoph Hammerschmidt
Power management solutions provider Eaton Corp. has introduced a serves of electric fuses that take into account the specific requirements of electric vehicles.

The new Bussman fuses are specifically designed to protect sensitive electric and hybrid automotive equipment, including high voltage, high capacity batteries, power conversion equipment, contactors, cabling and other auxiliary circuits – enhancing electrical system safety and reducing potential warranty costs.

With protection as low as 135 percent of rated current, Bussman series EV fuses can protect a wider range of overcurrent conditions while avoiding nuisance operations associated with cycling fatigue. Additionally, the fuses are engineered with a 20 kilo ampere (kA) interrupting rating to enable longer vehicle range by protecting higher capacity and more efficient batteries with higher fault currents.

The compact and lightweight Bussman series EV fuse design requires up to 48 percent less space and weighs up to 50 percent less when compared with traditional high speed fuses used for electric vehicles. This compact form factor also helps achieve longer vehicle range by enabling smaller assemblies and improved energy efficiency.

The fuses feature an 11 % higher voltage rating than the Japanese Automotive Standards Organization (JASO) D622 specification to help eliminate the need to redesign or revalidate circuit protection as battery systems develop and are optimized for higher voltages. Through robust quality planning and design tools, the new series of EV fuses are also engineered to the principles of the Automotive Industry Action Group (AIAG), Advanced Product Quality Planning (APQP) and Design for Six Sigma (DFSS) processes.

The fusible solutions are available in three bolt-on case sizes to protect high power battery charging and management systems up to 500 volts DC in ratings from 50 to 400 A. Compact 10x38 mm fuses are also available to protect auxiliary electrical systems up to 500 Vdc in ratings that span 5 to 50 amps and feature four termination styles to match application needs.

For EV circuit protection requirements above 500 volts, Eaton offers customer-specific designs. High performance fuses with ratings over 1000 Vdc and 1000 amps are available to cover