EV/HEV High Voltage Fuses Future Challenges

The growing popularity of EV/HEV High Voltage Fuses will ensure a high growth market for fuses, but the evolving electrification of vehicles is adding complexity to fuse applications.

a) EV/HEV fuse usage standards are causing problems

As EV/HEV High Voltage Fuses electrical solutions continue to evolve, OEMs are building models with more power, greater range, and faster charging, and for higher voltage platforms (800 to 1000VDC), fuses will lack certification standards. There are no fully unified regulations for high voltage fuses for new energy vehicles worldwide, and the lack of a global certification system for fuses makes it possible for different OEMs and product suppliers to adopt conflicting product specifications/designs, making the entire electrical system design of the vehicle face time and additional cost challenges.

In addition, the size and weight of fuses will face design challenges as the vehicle DC voltage plateau rises and OEM customer specific requirements continue to intensify.

b) EV/HEV fuse system integration challenges

In addition to the inadequacy of the existing standards system, OEMs will not only need to select fuses on a component-only basis, but will also need to use them as part of the system. This means that fuses are required to meet standard specifications not only at the component level (as an individual), but also at the system level (when working with other electrical equipment) to meet functional characteristics.

The need for fuses to meet EV/HEV system integration performance will pose additional challenges for automotive fuse manufacturers. For example, the start/stop and acceleration characteristics of different EV/HEVs are not clearly defined, and the fuse matches a random and variable load current profile, which requires fuse manufacturers to work more closely with OEM model platform development.

c) Lack of service capability of Chinese fuse brands

With the rapid development of the domestic new energy industry, domestic fuse brands have emerged in the past two years, and their identity is slowly changing from imitators/chasers of foreign products to competitors as independent brands. What is worrying is that some domestic brands are conquering the market while focusing only on product price rather than professional service value – product quality control is too simple, test reports are too formal, and fault analysis capability is simple and crude.

With the abolition of the share ratio restrictions in China’s auto industry, it is foreseeable that the pattern of the new energy industry and parts industry is bound to change in the future, and the only way for Chinese fuse brands to occupy a place at this stage is to continuously improve their professional service capabilities.

IV] Summary

Because of the diversity of application conditions faced by EV/HEV, it seems impractical to use a single method to match the design of all models. Fuses are one of the most important electrical components in EVs and HEVs. As a one-time irreversible protection element, it means that once broken, the vehicle will face the risk of losing power or other risks during normal driving, so the correct selection of fuses is very important and critical to the vehicle.

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