Electric vehicle power distribution and drive control modules

A heavy duty vehicle propulsion system for a vehicle comprising a chassis comprising a forward portion and a rearward portion, and a cab mounted on the chassis, the system comprising:

• a power distribution module comprising a frame and a housing mounted to the chassis of the vehicle rearward of the cab, the housing enclosing a power distribution component disposed and an inverter disposed therein;
• a cable interface coupled with the chassis and coupled with the power distribution module, the cable interface comprising a first junction and a second junction;
• a power source coupled to the first junction, wherein the power source comprises a battery assembly that is separate from the power distribution module and mounted to the chassis at a location spaced apart from the frame of the power distribution module and outside the housing thereof;
• an electric motor coupled to the second junction, the electric motor coupled to a drive axle supported by the chassis to drive wheels of the vehicle;
• a cable routing area positioned within the housing of the power distribution module, wherein a first cable routing path is provided between a plurality of vertically oriented cable junction locations of the power distribution component and one or more inverters and wherein a second cable routing path is provided between the one or more inverters and an inverter cable junction of the cable interface.

A heavy duty vehicle power distribution system, the system comprising:

• an electric vehicle control module, comprising:
• an electric vehicle control module frame assembly comprising a plurality of frame members configured to support components of the electric vehicle control module and a frame rail bracket for coupling the electric vehicle control module with a vehicle frame rail behind a cab thereof;
• a power distribution component coupled with the electric vehicle control module frame assembly;
• and
• a cowling disposed around the power distribution component, the cowling enclosing a space free of batteries configured to supply current to a vehicle electric motor;
• and
• a cable interface coupled with the electric vehicle control module, the cable interface comprising a first junction and a second junction;
• a power source disposed outside the cowling and configured to be mounted to a vehicle frame rail separately from the electric vehicle control module;
• wherein the first junction is configured to connect the power distribution component with the power source and the second junction is configured to connect the power distribution component with a load;
• at least one inverter configured to transform DC current from the first injunction to AC current to be provided to the second junction;
• wherein the power distribution component comprises a third junction disposed on or in the power distribution component;
• and
• wherein a first inverter cable routing path is provided between the third junction and one or more inputs of the at least one inverter.

A vehicle comprising:

• a chassis comprising a first longitudinal frame rail, a second longitudinal frame rail spaced apart from the first longitudinal frame rail and a cab supported on a forward portion of the frame rails;
• a power distribution system, comprising:
• an electric vehicle control module, comprising:
• an electric vehicle control module frame assembly comprising a plurality of frame members configured to support components of the electric vehicle control module and a frame rail bracket coupling the electric vehicle control module with the one or more frame rails of the chassis behind the cab thereof;
• a power distribution component coupled with the electric vehicle control module frame assembly, wherein the power distribution component comprises a first plurality of vertically oriented cable junction locations;
• and
• a fuel cell module comprising a fuel cell;
• a cowling disposed around the power distribution component and the fuel cell module such that the fuel cell extends transversely to and in a space above and a gap between the frame rails;
• and
• a cable interface coupled with the electric vehicle control module, the cable interface comprising a first junction and a second junction, the first and second junctions configured to connect the power distribution component with a power source and a load respectively, the cable interface further comprising a third junction and a fourth junction, the third junction disposed vertically below the first plurality of vertically oriented cable junction locations;
• a cable routing area positioned within the cowling, wherein a first cable routing path is provided between the third junction and the first plurality of vertically oriented cable junction location and a second cable routing path is provided between the power distribution component and the fourth junction;
• and
• wherein the electric vehicle control module is mounted to the frame rails directly behind the cab.