Sponsored by Eaton.
Transforming the Path to Safe, Reliable and Efficient EVs
With electric vehicle (EV) technology rapidly evolving, it is critical to expand the scope of vehicle safety considerations. Eaton combines automotive and commercial vehicle expertise with electrical insight to deliver proven, safety-critical technologies that ensure protection for both people and EV systems. With global R&D and manufacturing capabilities, Eaton’s innovations reflect a deep understanding of the challenges and opportunities associated with the transition to electric transportation.
Intelligent, safe and reliable technology
At the forefront of Eaton’s advancements is Breaktor® circuit protection technology, an advanced circuit protection solution tailored for electric vehicles. As EV power levels soar, coordination between fuses and contactors becomes increasingly complex. Breaktor addresses this issue by combining the functions of fuses, pyroswitches and contactors into one coordinated device.
This innovation not only simplifies the architecture by replacing up to 15 components with one unit, but also improves safety and reliability. With a rapid trip time of less than 4 milliseconds for short circuit faults up to 900 volts and 25,000 amps, Breaktor provides superior protection for high-power battery and inverter systems. Its resettable nature, similar to a circuit breaker, ensures cost-effectiveness for both OEMs (original equipment manufacturers) and consumers, and allows for restart after a functionality check.
Breaktor’s benefits are further extended by its self-triggering, current limiting and independent operation from current direction, supporting both charging and duty use with full electrical loads. Available in multiple configurations, Breaktor accommodates a variety of voltage levels and multi-pole designs, solidifying its role as a versatile and essential component in the EV ecosystem. Learn more about Breaktor.
EV Battery Safety and Efficiency
Complementing the Breaktor circuit protection technology is Eaton’s 3-in-1 battery pack vent valve, designed to enhance the safety and efficiency of EV batteries. This innovative valve offers three unique features: overpressure relief with passive and active venting and includes a pioneering battery case leak check mechanism. This leak check feature eliminates the traditional need to install a vent valve as the final step in battery assembly, streamlining the process and ensuring thorough testing of sealing surfaces. Eaton’s tool, which activates the leak check mechanism on the assembly line, facilitates this process, ensuring a robust, reliable battery pack.
The 3-in-1 battery vent valve is precision engineered to meet specific opening pressures, optimizing venting and featuring proven reseal technology. Spring-based actuation technology accommodates a wide range of pressure requirements and promotes economies of scale. The valve’s low-flow breathing mode allows pressure to normalize during normal operation, and it can be assembled with robust quick-connect features or threaded metal-to-metal connections for flexibility and reliability. Learn more about EV battery vent valves.
Eaton Bussman Series EV Fuses and Pyro Safety Switches: Optimal EV System Protection
Eaton’s Bussmann® EV Series fuses are rated up to 1,000 volts direct current (VDC) and up to 1400 amps and are designed to protect the charging systems of commercial electric vehicles, passenger cars, and high performance vehicles. These fuses isolate energy and interrupt the circuit during a severe short circuit, ensuring the safety and integrity of EV systems. Eaton’s proprietary simulation testing and innovative design dissipate heat away from weak points, improving fuse reliability and life, while requiring less space and weight than traditional solutions.
The Bussmann EV series now includes pyrofuses rated at 1,000 VDC and 400 A continuous current. Pyrofuses are offered in traditional single trigger and dual trigger types with a self-triggering mechanism that can isolate a short circuit event without an external trigger, improving functional safety. Learn more about the Bussmann® series EV fuses.
Hybrid Fuel Tank Safety
In the hybrid vehicle sector, Eaton’s next generation Fuel Tank Shut-Off Valve (FTIV) is a major advancement. Hybrid vehicles often operate in electric mode, causing pressure to build up in the fuel tank that must be relieved to prevent evaporative emissions and ensure safe refueling.
Eaton’s new FTIV addresses these needs with increased efficiency, being 27% lighter, 39% smaller, and featuring 24% fewer parts than its predecessor. The FTIV’s reduced size and weight simplify installation into a variety of tank configurations, while improving magnetic force and maintaining reliability with reduced copper content. Learn more about the FTIV here.
Space-saving profile, great performance
Eaton’s High Power Lock Box (HPLB) power connectors further demonstrate the company’s commitment to innovation. Designed for use in current and future electric and internal combustion vehicle solutions, these connectors offer a space-saving profile, superior performance, reduced cost and manufacturing complexity. Sealed to prevent corrosion and withstand severe vibration, HPLB connectors ensure reliable power flow that meets USCAR safety performance requirements. The unique connection system improves contact force and reduces heat, improving the overall performance and lifespan of vehicle systems. Learn more about HPLB.
Through these breakthrough technologies, Eaton is not only addressing the EV market’s current challenges, but also anticipating future needs and paving the way for a safer, more efficient and reliable electric vehicle environment.
Learn more about how Eaton is revolutionizing the way electric vehicles are made safe, reliable and efficient: Eaton.com/eMobility
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