Show notes
Key takeaways from this episode:
- Most high voltage systems within an electric vehicle today are also protected with fuses.
- The fuses are meant to protect against much larger current and voltage levels (as compared to gas vehicles) due to the power levels of the batteries.
- We’re seeing a transition to alternative circuit protection methods, such as electromagnetic disconnecting devices and some solid-state solutions, as the power levels and voltages and currents need to increase.
- One of the most common misconceptions related to EV safety is that electric vehicles are inherently less safe than gas or diesel vehicles because of this large amount of stored electrical energy.
- Gasoline contains a lot of stored chemical energy, so in reality both gas and electric vehicles have a large amount of stored energy so one cannot identify one as safer than the other, however different considerations must be accounted for when comparing the two.
- Short circuits are not a common occurrence in electric vehicles, however the size of the battery can impact the severity of a short circuit event
- A larger battery does not increase the likelihood of a short circuit.
- Faster charging speeds mean higher current levels so more robust electrical system components are required.
- Although regulations vary by region, most focus on CO2 emissions reduction and fuel economy improvement across a fleet of vehicles.
- Functional safety is among the biggest electrical system challenges that EV manufacturers face.
- Functional safety can be improved is by implementing diagnostics or redundancies in the electronics to ensure a safety, even if one of the critical components malfunction.
- Technology innovations like Breaktor™ circuit protection, which is a combination of a circuit breaker and a contactor, is designed to improve the functional safety of an electric vehicle circuit protection system.
- To increase overall safety of electric vehicle systems, OEMs can work to ensure that any level of unsafe current the battery can produce can be safely protected. And OEMs can consider implementing advanced protection devices, like Breaktor, that are designed to improve functional safety of the protection system.
To learn more, visit Eaton.com/eMobility.
Guest bio
Kevin Calzada is the Global Product Strategy Manager – Power Distribution and Circuit Protection systems, for the eMobility business at Eaton. In this role, Calzada is responsible for defining the short and long-term product strategy and product development roadmaps for high voltage power distribution and protection systems for on-and off-road vehicles.
Calzada joined Eaton, eMobility from Eaton’s Bussmann business where he had multiple roles in operations, engineering, product management, and sales. Most recently, he was the sales manager responsible for circuit protection solutions in the electric vehicle market.
He holds a Bachelor’s and Master’s degree in Mechanical Engineering from the University of Illinois – Urbana-Champaign.
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I've learned that one of the most critical parameters is this concept of functional safety. It's a big challenge. And as you can imagine, the circuit protection system is certainly a critical component. As a result, there needs to be a way to design out unacceptable risks.
Interested in learning more?
Check out to Kevin Calzada's webinar presentation on next generation circuit protection for electric vehicles hosted by CHARGED.
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