Vehicle electrical interconnection system
Electrified vehicle electrical systems and formatting methods include arranging a first layer including one or more first electrical transmission lines each configured to carry electrical power at a first voltage to one or more electrical powertrain components of the electrified vehicle, arranging a second layer above at least a portion of the first electrical connection layer, wherein the second layer includes one or more second electrical transmission lines each configured to carry electrical power at a second voltage to one or more electrical power distribution components of the electrified vehicle, and arranging a third layer above at least a portion of the first and second layers, wherein the third layer includes one or more third electrical transmission lines each configured to carry electrical power at a third voltage to one or more input/output device components of the electrified vehicle.
1 . An electrical system for an electrified vehicle, the electrical system comprising:
a first electrical connection layer arranged upon a base of an electrified vehicle and including one or more first electrical transmission lines each configured to carry electrical power at a first voltage to one or more electrical powertrain components of the electrified vehicle, wherein the first voltage is greater than 60 volts;
a second electrical connection layer arranged above at least a portion of the first electrical connection layer and including one or more second electrical transmission lines each configured to carry electrical power at a second voltage to one or more electrical power distribution components of the electrified vehicle, wherein the second voltage is less than the first voltage; and
a third electrical connection layer arranged above at least a portion of the first and second electrical connection layers and including one or more third electrical transmission lines each configured to carry electrical power at a third voltage to one or more input/output device components of the electrified vehicle,
wherein the third voltage is less than or equal to the second voltage, and
wherein the third voltage is selected from the group consisting of 48 volts, 24 volts, 12 volts, 5 volts, and 3.3 volts.
2 . The electrical system of claim 1 , wherein the one or more first electrical transmission lines are each connected to a first electrical power source configured to output the first voltage.
3 . The electrical system of claim 2 , wherein the first electrical power source is a battery system of the vehicle that is also arranged upon the base of the electrified vehicle.
4 . The electrical system of claim 3 , wherein:
at least one electrical powertrain component is an electric traction motor configured to propulsion of the electrified vehicle;
at least one first electrical transmission line includes a rigid busbar arranged substantially parallel to a length of the electrified vehicle; and
the first voltage is sufficient for powering the electric traction motor.
5 . The electrical system of claim 4 , wherein the electrified vehicle further includes a vehicle body arranged above the first electrical connection layer, and wherein the second and third electrical connection layers are arranged upon the vehicle body.
6 . The electrical system of claim 1 , wherein the electrical system defines at least two zones corresponding to outlying sides or corners of the electrified vehicle, and wherein the electrical system further includes zone controllers for the zones, respectively, wherein each zone controller is configured to control input/output from/to functional devices and sensors associated with the respective zone of the electrified vehicle.
7 . The electrical system of claim 1 , wherein one or more of the second electrical transmission lines of the second layer is configured to carry data to one or more controllers of the electrified vehicle.
8 . A method of forming or installing an electrical system for an electrified vehicle, the method comprising:
arranging a first electrical connection layer upon a base of an electrified vehicle, wherein the first electrical connection layer includes one or more first electrical transmission lines configured to carry electrical power at a first voltage to one or more electrical powertrain components of the electrified vehicle, and wherein the first voltage is greater than 60 volts;
arranging a second electrical connection layer above at least a portion of the first electrical connection layer, wherein the second electrical connection layer includes one or more second electrical transmission lines each configured to carry electrical power at a second voltage to one or more electrical power distribution components of the electrified vehicle; and
arranging a third electrical connection layer above at least a portion of the first and second electrical connection layers, wherein the third electrical connection layer includes one or more third electrical transmission lines each configured to carry electrical power at a third voltage to one or more input/output device components of the electrified vehicle, and wherein the third voltage is selected from the group consisting of 48 volts, 24 volts, 12 volts, 5 volts, and 3.3 volts,
wherein the electrified vehicle further includes a vehicle body arranged above the first electrical connection layer, and wherein the second and third electrical connection layers are arranged upon the vehicle body.
9 . The method of claim 8 , wherein the one or more first electrical transmission lines are each connected to a first electrical power source configured to output the first voltage.
10 . The method of claim 9 , wherein the first electrical power source is a battery system of the vehicle that is also arranged upon the base of the electrified vehicle.
11 . The method of claim 10 , wherein:
at least one electrical powertrain component is an electric traction motor configured to propulsion of the electrified vehicle;
at least one first electrical transmission line includes a rigid busbar arranged substantially parallel to a length of the electrified vehicle; and
the first voltage is sufficient for powering the electric traction motor.
12 . The method of claim 8 , wherein the electrical system defines at least two zones corresponding to outlying sides or corners of the electrified vehicle, and wherein the electrical system further includes zone controllers for the zones, respectively, wherein each zone controller is configured to control input/output from/to functional devices and sensors associated with the respective zone of the electrified vehicle.
13 . The method of claim 8 , wherein one or more of the second electrical transmission lines of the second layer is configured to carry data to one or more controllers of the electrified.