According to foreign media reports, power management company Eaton announced that its electric mobility (eMobility) business unit has launched a battery disconnect device (BDU), which can be combined with the upgraded Breaktor circuit protection technology to protect the circuits of electric vehicles (EVs) while reducing overall complexity and cost.
Breaktor circuit protection technology combines current switching with resettable fast-drive bidirectional short-circuit protection. When combined with this technology, Eaton's BDU eliminates the need for up to 15 additional system components. Conventional systems require a combination of high-temperature fuses and thermal fuses and contactors.
Kevin Calzada, Global Product Strategy Manager, Eaton's E-Mobility Business Unit, said: "As manufacturers continue to increase the power levels of electric vehicles, it is becoming increasingly important to have robust and reliable protection solutions. Combining our BDUs with Breaktor circuit protection technology enables compact and efficient packages with performance needs to protect vehicles and passengers. "
The main function of this BDU is to act as a switch for the battery depending on the EV's mode of operation, such as charging or driving. There are three traditional BDU configurations that EVs can use today: fuses and contactors; high-temperature fuses and contactors; or fuses, high-temperature fuses and contactors, all of which can be used together in a single BDU. While these configurations provide switching and protection functions, they all have disadvantages such as overall system complexity, low maintainability, difficult coordination, and fatigue at high current levels.
Adding Breaktor circuit protection technology to Eaton's BDU provides additional features and benefits, including active and passive drive in a single device; the ability to transition to a shutdown state under various fault conditions; improve functional safety; the ability to reset after a high-energy failure; and the ability to replace up to four high-voltage electrical components, reducing complexity and system-level costs.
"The self-triggering design, diagnostic electronics, and mirrored contacts of our Breaktor circuit protection technology contribute to the BDU functional safety goals," Calzada added. With its integrated coil driver, economizer, and inductive/trigger circuitry, Breaktor circuit protection technology also reduces the cost and complexity of battery management systems. "
When used to protect and switch DC fast charging circuits, Eaton's Breaktor circuit protection technology can also enable DC fast charging of up to 350 kW, enabling electric vehicles to be charged in 15 minutes or less. That's because the latest upgrade to Breaktor circuit protection technology has thermal management features and heatsinks for increased power handling. When utilizing an active or passive cooling system, Breaktor circuit protection technology is capable of continuously carrying 500 amps and up to 750 amps of continuous current.
"The Breaktor achieves best-in-class current ratings and can be further improved with a proper cooling strategy," says Calzada. Eaton is able to design and develop compatible cooling systems to customer specifications and integrate them into BDU to meet growing power requirements. "
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