1. Copper Busbars Copper busbars serve as the main conductive pathways, connecting relays, resistors, and shunts to route high-voltage electricity efficiently during charging and discharging processes . 2. High-Voltage Relays and Fuses Relays control the connection and disconnection of high-voltage circuits, while fuses provide overcurrent protection to prevent damage to the battery and vehicle electronics . 3. DC/DC Converter The DC/DC converter steps down high-voltage DC from the battery to low-voltage DC required by vehicle electronics, ensuring stable operation of lights, infotainment, and control systems . 4. Onboard Charger (OBC) The OBC converts AC from the public grid into high-voltage DC to charge the battery. In many modern vehicles, OBC and DC/DC functions are combined into a two-in-one controller for compactness and efficiency . 5. High-Voltage Wiring Harness Specialized high-voltage wiring connects all components within the distribution box and to external high-voltage devices like motors, compressors, and PTC heaters. Safety and insulation are critical due to the high voltage involved . 6. Additional Components Some distribution boxes integrate cement resistors, shunts, and electric compressors. Shunts measure current flow, resistors manage transient loads, and compressors or PTC heaters support thermal management of the battery .
The high-voltage distribution box acts as a central hub for power management, coordinating current flows, monitoring circuit integrity, and interfacing with battery management and thermal control systems. It ensures safe, efficient energy distribution to components such as motors, air conditioning compressors, and battery preheating systems . Modern designs also emphasize compactness, weight reduction, and diagnostic capabilities to meet evolving EV performance and safety standards .
The functions of the high voltage distribution box are shown in the following table:
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