Bus-bar Type Auto Fuse And Relay Box Design

Vehicle electrical box is the core of automotive electrical system,which plays an important role in circuit allocation and protects electrical wiring in vehicle.According to its structure and property,the electrical box can be divided into five categories,that is,Direct plug-in box,PCB type,Bus-bar box,Electronic integrated box,and High voltage electrical box.Direct plug-in Fuse and Relay box is widely used in many vehicles because of its simple structure and low cost.However,the box has some disadvantages,for example,it has a large volume,complex wiring connection,and a high maintenance cost;what's more,it's difficult to change terminals.PCB Fuse and Relay box can't carry large current because of its limited bonding copper thickness;in addition,it has a higher cost than Direct plug-in box;so it is limited in application.The most remarkable advantage of Bus-bar Fuse and Relay box is that it can carry large current with a high reliability,it is widely used in all kinds of vehicles.The traditional bus-bar electrical box can't achieve the overall layout for it has the bus-bar structure,which would lead to the lower productive efficiency and a higher cost.Therefore,we should ameliorate the structure of the traditional bus-bar electrical box and the bus-bar structure,which has a great value to improve the assembly efficiency,reduces the assembly cost and improves the reliability of the product.This thesis studys the basic characteristics,forming characteristics and main performance parameters of commom engineering materials,analyses the the design pricinple of plastic parts,develops the assembly technology of the electrical box.On the basis of the electrical function,I analyse the feasibility of the same layer with multi bus,study the scheme of product design,design the manufacturing technology of bus-bar.In the end,I achieve the overall stamping formation.According to the budget,the manufacturing cost is greatly reduced.This paper takes the plastic board as an example,I analyze the warping and deformation of plastic board by Moldflow,take relevant measures to the critical situation and improve the reliability of the assembly.The technology has been successfully applied to a certain type of vehicle.All the test and real vehicle test in the road indicate that all the performance and index reach the national standard.The practical application proves the rationality of the design.