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Electric vehicle (EV) systems must safely and reliably protect people and components during all load situations including short circuits, overloads and collision events, as well as quick charging and normal driving scenarios. The battery disconnect unit (BDU) does exactly that.
Featuring Breaktor® circuit protection, the BDU essentially acts as an on/off switch to the battery for different operating modes in an EV. It is also designed to efficiently distribute and protect power throughout the EV system.
The BDU functions throughout several modes of operation including charging, driving, accelerating and decelerating (or regenerating power). The protection function engages when, for example, the car is in a collision, or another overcurrent event takes place. In these situations, the BDU will disconnect power to ensure the safety of the occupants and other components.
Eaton has a legacy of protecting high power systems with advanced technology from our Electrical Sector. The BDU leverages this technology with the integration of our own components. This allows for innovative packaging and competitiveness with superior system protection.
Breaktor circuit protection technology is exclusive to Eaton and is able to accomplish both switching and protection of the system all in one unit. By combining the function of multiple components in the traditional BDU, Breaktor allows us to eliminate up to 15 components, reducing both cost and complexity. These components include:
Since it’s an all-in-one unit, Breaktor also eliminates the connection components between those parts, including busbars, fasteners, connectors, and content in the BMS like triggering circuits and contactor drivers/economizers.
In addition to enabling a simplified architecture, Breaktor is also a game changer when it comes to protecting EV systems. Similar to a circuit breaker, it is resettable in the event of an overcurrent. This resettability eliminates the concern of contactor welding, one of the key warranty issues for some hybrid and electric vehicles on the market today. As a matter of fact, the integration of Breaktor in the BDU is estimated to save thousands of dollars in repair costs for vehicle owners not to mention warranty costs for OEMs.
The BDU is designed specifically for electric passenger vehicles, but we do have a solution for commercial vehicles as well. The FLEX power distribution unit (FLEX PDU) integrates many of the components and offers the same benefits as the BDU but is a unique platform for commercial applications.
Find more information on the BDU as well as other eMobility products and solutions at eaton.com/emobility.
eMobility is a new business within Eaton that combines elements of our Electrical and Vehicle businesses to deliver electric vehicle solutions to passenger car, commercial vehicle and off-highway OEMs.
Learn about Eaton’s portfolio of eMobility products and solutions for electric vehicles and beyond. Try the interactive version or download the PDF now.
