Eaton’s eMobility Business Introduces Battery Disconnect Unit with Up-to-Date Breaktor® Circuit Protection Technology

GALESBURG, Michigan – (BUSINESS THREAD) – Eaton’s power management company announced today that its eMobility business has introduced a battery disconnection unit (BDU) that can be combined with the upgraded Breaktor.® circuit protection technology to provide circuit protection in electric vehicles (EVs) while reducing overall complexity and costs.

When combined with Breaktor circuit protection technology, which combines current switching and reset short-circuit reversible protection with quick activation, Eaton’s BDU eliminates the need for 15 additional components to the system. Traditional systems require a combination of fuses and pyro and thermal contactors.

“As manufacturers continue to increase the power levels of electric vehicles, it is becoming increasingly important to have capable and reliable protection solutions,” said Kevin Calzada, Eaton’s global eMobility product strategy manager. “Our BDU, combined with our Breaktor circuit protection technology, provides everything you need to protect your vehicle and occupants in a compact and efficient package.”

The main function of the BDU is to act as a battery on / off switch, depending on how the EV works, such as charging or driving. Current electrical models are based on one of three traditional BDU configurations: fuse and contactor; fuse and contactor; or fuse, fire extinguisher, and contactor, all used together in a single BDU. Although they all offer switching and protection functions, each has disadvantages, such as the overall complexity of the system, the availability of the service, the difficulties of coordination, and the susceptibility to fatigue at high current levels.

Adding Breaktor circuit protection technology to Eaton’s BDU provides additional functionality and benefits, including active and passive actuation on a single device; the ability to move to an external state in a variety of fault conditions; improved functional safety; the ability to recover after a high-energy breakdown; and the ability to replace four high-voltage electrical components, which reduces complexity and system-level cost.

“The design, electronic diagnostics and mirror contacts of our Breaktor circuit protection technology help achieve the goals of BDU functional safety,” Calzada said. “With its coil driver, economizer and sensing / starter circuit, Breaktor circuit protection technology reduces the cost and complexity of the battery management system.”

Eaton’s Breaktor circuit protection technology also enables 350 kW of fast DC charging when used to protect and change the fast-charging DC circuit, allowing EVs to charge in 15 minutes or less. This capability has been made possible thanks to the latest innovations in thermal management of technology to protect the Breaktor circuit and materials to increase energy capacity. Breaktor circuit protection technology is currently capable of carrying 500 amp and 750 amp direct current when using an active or passive cooling system.

“Breaktor achieves the best levels today, and these can be further enhanced with a proper cooling strategy,” Calzada said. “Eaton is able to design and develop a compatible cooling system to customer specifications and integrates it into a BDU to meet these rising power requirements.”

Learn more about Eaton’s battery disconnect unit.

Eaton is a smart energy management company dedicated to improving the quality of life and protecting the environment for people everywhere. We are driven by our commitment to doing business right, operating sustainably, and helping our customers manage their energy, today and in the future. Taking advantage of the growing global trends in electrification and digitalization, we are accelerating the transition to renewable energy on the planet, helping to address the most pressing energy management challenges in the world, and doing the best for our stakeholders and society as a whole.

Founded in 1911, Eaton has been on the NYSE for nearly a century. In 2021, we provided $ 19.6 billion in revenue and served customers in more than 170 countries. For more information, visit Follow us on Twitter and LinkedIn.

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