Beta 1 High Voltage Junction Box (HVJB) //
Beta 1 High Voltage Junction Box (HVJB) //
Sole design engineer of a fully custom High Voltage Junction Box used in our Beta 1 Builds.
I designed and architected everything from scratch. Everything from the layout, to the busbars, to the billet aluminum panels, to the form factor of the PCB board and its packaging and integration, as well as all the internal harnessing. All this while still meeting all durability and safety requirements.
The HVJB facilitates power flow in multiple different scenarios. These are:
HVDC power flowing to the HV battery from various sources, including
From the charge port (DC fast charging)
From the On-board charger (AC charging)
From the 12v DC-DC converter (in boost mode)
From the drive unit (regenerative braking)
HVDC power flowing from the battery pack to various HV components, including:
Drive unit (motoring)
12v DC-DC converter (in buck mode)
OBC (in V2X mode)
HV compressor
HV sensing to check HVDC voltage, and confirm AC vs DC input on NACS charge port
HV isolation check to test HV isolation to ground
Current sensing to determine amperage of current flow (AC and DC)
AC power flow from AC mains (L1/L2 AC connections) to OBC and AC junction box
Beta 2 HVJB
Billet HVJB internals
Hooked up and working!
System diagram I created
IP testing..
More leak testing..
CAD of the underbody of the vehicle that I did, I positioned all the batteries, created all the harnessing, and conceptualized and executed on the overall package. A different engineer was responsible for the frame however.
Installed in a vehicle
Cast version I designed that we didn't end up making since we didn't want to commit to tooling just yet
Cast enclosure
Top view of cast design
The difference between the billet aluminum version and a 3D print of the cast version
