The FUSION high-voltage distribution system
The all-connecting component
In the high-voltage distribution system (HVDU or High Voltage Distrubution Unit) also known as Power Distribution Unit (PDU) or Junction Box, all high-voltage components of a fully electric or hybrid machine are connected to each other. The batteries can be connected here to the charger, the fast charging interface as well as to the loads such as electric drive system and DC-DC converter.
Designed for use in construction equipment, in specialty and commercial vehicles such as municipal vehicles and in agricultural vehicles, the FUSION can withstand the harshest and most extreme conditions with its rugged aluminum housing, high-quality metal cable glands or connectors and IP67 protection rating. Thanks to expert design at our development facility in Switzerland, high-quality internal components, and meticulous in-house manufacturing and testing, voltages up to 800 V and currents up to 500 A (model dependent) can be handled reliably and continuously.
Various sizes and voltage classes of the FUSION are available - with individually configurable inputs and outputs to provide the perfect solution for every application. With the INTERFUSION800M, the high-voltage distribution of a FUSION800M is combined with the fast-charging interface of the INTERFLOW500, providing a more compact and elegant solution when both components are needed. Furthermore, with the optional additional development and manufacturing of the electrical system
with the wiring harnesses by SUNCAR, a plug and play complete solution is available.
Safety has top priority
The FUSION high-voltage distribution system also features numerous safety features. Each individual input and output is reliably protected by high-quality fuses. A temperature sensor and a pressure compensation element are also installed. During maintenance work, the system can first be checked for the absence of voltage by means of dedicated measuring points before the safety cover is removed and a short-circuit bar in accordance with the high-voltage guideline guarantees the absence of voltage during maintenance. In addition, the FUSION is integrated into the machine-wide interlock system (HVIL) with the interlock switch. When a component of the HV system is opened, this triggers the interlock system and opens the battery contactors, which disconnect the machine from the power source. The enclosure can be grounded at the grounding stud and is also connected to the conductive cable sheath (shielding) of the input and output cables by means of the EMC cable glands to intercept and ground electromagnetic interference (EMI). If required, an insulation monitoring device (IMD) can be integrated for continuous insulation measurements, constantly monitoring the system for possible electrical leaks during operation.
SUNCAR also offers expert advice on the product and development support from electrical design to the construction of complete prototypes or small series. If you are interested in the FUSION high voltage distribution system or any other service, please contact us