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High-voltage power distribution and protection

Battery disconnect unit

The battery disconnect unit (BDU) is designed to efficiently distribute power throughout the electric vehicle (EV) system. Acting as an on/off switch to the battery for different EV operating modes, the BDU plays a critical role in achieving functional safety goals. With a legacy of safeguarding high-power systems, Eaton’s BDU provides customized circuit protection that meets OEM performance requirements while reducing system complexity.

With the integration of Breaktor circuit protection technology, Eaton Bussmann series EV fuses or pyro fuses, the BDU supports innovative packaging that delivers superior system protection. The optional integration of Breaktor enables the reduction of up to 15 components from the BDU assembly. Additionally, its self-triggering design, diagnostic electronics and mirror contact help to ensure utmost safety and reliability.

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DC FAST CHARGING
Enables up to 600A continuous current at 800V - compatible with 400kW DCFC
SENSING CONTROL
Available with current, voltage and temperature sensing and isolation detection
FUNCTIONAL SAFETY
Integration of Breaktor, EV fuses or pyro fuses to achieve functional safety goals

Caratteristiche principali

  • Integration of Breaktor, Eaton Bussmann series EV fuses or pyro fuses to achieve BDU functional safety goals ​
  • Up to 600A continuous current at 800V and compatible with 400kWDC fast charging (which enables 15-minute charge times on BEVs)​
  • Available with current, voltage and temperature sensing and isolation detection​
  • Localized BDU sensing and control or integrated BMS capability can achieve up to ASILD​
  • Optional integration of Breaktor enables reduction of up to 15 total components​
  • BDU pre-charge circuit designed using power resistors or solid-state solutions
BDU-cutaway.jpg

The Battery Disconnect Unit (BDU) in an electric vehicle (EV) essentially acts as an on/off switch to the battery for different EV operating modes. In addition, the BDU distributes and protects power within 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.

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Eaton has a legacy of protecting high power systems with advanced technology from our Electrical Sector. Our BDU leverages this technology with the integration of our own components including:

This allows for innovative packaging and competitiveness with superior system protection.

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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:

  • Fuses
  • Contactors
  • Pyro switches

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.

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Breaktor is 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.
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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.
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Yes. The majority of the intellectual property (IP) rights we have for the BDU are around the circuit protection components (Breaktor and fuses). They also include the controller functions – pre-charge, isolation detection and current/voltage sensing.
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