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Old 11-24-2012, 12:47 PM   #21 (permalink)
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Another Update

A vendor has asked why the design uses one larger junction box, the BJB, instead of two smaller boxes.

Two smaller boxes would allow splitting the 12V signals like ignition ACC, Ignition RUN, Ignition START, Brake switch, accelerator switch, accelerator position, brake position, gas gauge, from the larger power signals connected to the charger, the batteries, and the motor.

The simple answer is because no one thought of it. It makes sense to separate the 12V signals from the higher voltage and higher current signals for many reasons. To name just one, NPFA 70E suggests voltages above 50V have finger-safe guards installed.

So the next iteration of the Big Junction Box will need new names. So far, Power Junction Box, PJB, and Signal Junction Box or SJB. That does not appear to conflict with anything else and will keep the labels separated.

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