High voltage wiring system for electric powertrains

• US 7,999,180 B2
• Filed: 11/30/2007
• Issued: 08/16/2011
• Est. Priority Date: 11/30/2007
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Sychra, Robert Roy, Lindsey, Robert Wayne
• Primary Examiner(s): Estrada; Angel R
• Application Number:
  US11/987,549
• Publication Number:
  US 20090139740A1
• Time in Patent Office: 1,355 Days
• Field of Search: 174/50, 174/50.5, 174/520, 174/17.R, 174/539, 174/564, 174/32, 174/17.GF, 307/9.1, 307/91, 307/24, 307/45, 307/86, 307/101, 180/65.1, 180/65.8, 180/122, 361/600, 361/601, 361/752, 361/796, 361/724, 318/803, 318/801
• US Class Current: 174/50.5
• CPC Class Codes: B60R 16/0215 Protecting, fastening and routing means therefor

Abstract

A high voltage wiring system for an electric powertrain is disclosed. The system includes a power conversion unit sealed in a first enclosure. The system also includes at least one second enclosure configured to be sealed and having at least one cable disposed therein. The disclosed system further includes a plurality of wiring termination compartments configured to provide a plurality of electrical termination points. The plurality of wiring termination compartments are separately encased in a material configured to provide a sealed barrier between an outside environment and the plurality of electrical termination points. The disclosed system further includes a source of at least one pressurized gas configured to substantially prevent the ingress of moisture into the first enclosure, the at least one second enclosure, and the plurality of wiring termination compartments.

Claims

1. An electric powertrain system, comprising:

a power conversion unit sealed in a first enclosure;

at least one second enclosure configured to be sealed, wherein at least one cable is disposed therein;

a plurality of third enclosures configured to be sealed and to provide at least one electrical termination point, the at least one electrical termination point being configured to provide an electrical connection between the first enclosure and the at least one second enclosure; and

a source to pressurize at least one gas and being configured to supply the pressurized at least one gas to the first enclosure, the at least one second enclosure, and the plurality of third enclosures.

2. The system of claim 1, further including at least one pressure monitoring device configured to monitor a pressure of at least one of the first enclosure, the at least one second enclosure, and the plurality of third enclosures, the plurality of third enclosures being a plurality of wiring termination compartments.

3. The system of claim 2, further including at least one electronic control module configured to:

monitor the at least one pressure monitoring device; and

send a signal to an operator, wherein the signal is indicative of the pressure of the at least one of the first enclosure, the at least one second enclosure, and the plurality of wiring termination compartments.

4. The system of claim 1, wherein the pressurized at least one gas is a non-conducting gas.

5. The system of claim 4, wherein the non-conducting gas is air.

6. The system of claim 4, wherein the non-conducting gas is nitrogen.

7. The system of claim 1, wherein:

the plurality of third enclosures are a plurality of wiring termination compartments; and

the first enclosure is electrically connected to at least one of the plurality of wiring termination compartments by the at least one second enclosure.

8. The system of claim 7, wherein the electrical connection is configured to allow for a flow of the pressurized at least one gas between the first enclosure, the at least one second enclosure, and at least one of the plurality of wiring termination compartments.

9. The system of claim 1, further including at least one check valve.

10. The system of claim 1, wherein:

the plurality of third enclosures are a plurality of wiring termination compartments; and

at least one of the plurality of wiring termination compartments is configured to provide an electromagnetic interference shielding for the plurality of electrical termination points.

11. The system of claim 1, wherein the at least one second enclosure is configured to provide an electromagnetic interference shielding for the at least one cable disposed therein.

12. The system of claim 1, wherein the at least one cable is at least one electrical wire.

13. The system of claim 1, wherein the at least one cable is at least one fiber optic cable.

14. The system of claim 1, wherein the pressurized at least one gas is further configured to substantially prevent the ingress of moisture into at least one power producing device and at least one power consuming device.

15. The system of claim 1, wherein the at least one electrical termination point is at least one of a plurality of electrical termination points, and the plurality of third enclosures are separately encased in a material configured to provide a sealed barrier between an outside environment and the plurality of electrical termination points.

16. The system of claim 1, wherein the pressurized at least one gas is configured to substantially prevent the ingress of moisture into the first enclosure, the at least one second enclosure, and the plurality of third enclosures.

17. A method of sealing a powertrain, comprising:

sealing a first enclosure, wherein a power conversion unit is located therein;

sealing at least one second enclosure, wherein at least one cable is located therein;

sealing a plurality of third enclosures, wherein at least one electrical termination point located therein is configured to provide an electrical connection between the first enclosure and the at least one second enclosure;

pressurizing at least one gas; and

supplying the pressurized at least one gas to at least one of the first enclosure, the at least one second enclosure, and the plurality of third enclosures.

18. The method of claim 17, wherein the at least one gas is non-conducting.

19. The method of claim 17, further including shielding at least one of the plurality of third enclosures from electromagnetic interference.

20. The method of claim 17, further including relieving a pressure from at least one of the first enclosure, the at least one second enclosure, and the plurality of third enclosures.

21. The method of claim 17, further comprising monitoring a pressure from at least one of the first enclosure, the at least one second enclosure, or the plurality of third enclosures.

22. The method of claim 21, further including sending a signal to an operator, wherein the signal is indicative of the monitored pressure from the at least one of the first enclosure, the at least one second enclosure, and the plurality of third enclosures.

23. A machine, comprising:

at least one power producing device;

at least one power consuming device;

a power conversion unit sealed in a first enclosure;

at least one second enclosure having at least one electrical wire disposed therein;

a plurality of wiring termination compartments configured to provide an electrical termination point for electrically connecting the at least one power producing device, the at least one power consuming device, and the power conversion unit, wherein the plurality of wiring termination compartments are separately encased in a material configured to provide a sealed barrier between external environment and the electrical termination point; and

at least one pressure source configured to provide at least one non-conductive positive pressure gas to at least the first enclosure.

24. The machine of claim 23, further comprising at least one pressure release device.

25. The machine of claim 23, further comprising:

a pressure monitoring device configured to monitor a pressure in at least one of the first enclosure, the at least one second enclosure, and the plurality of wiring termination compartments; and

an electronic control module configured to monitor the pressure monitoring device and send a signal to an operator, wherein the signal is indicative of the pressure of the at least one of the first enclosure, the at least one second enclosure, and the plurality of wiring termination compartments.