Better Overload Protection, Fewer Warranty Claims Thanks to GEP’s INMIDI and INMEGA In-Line Fuse Holders
All-terrain vehicles often rely on high-current peripheral components such as winches and plows, which require dependable overload protection in harsh outdoor environments. When a leading ATV manufacturer faced repeated issues with exposed fusible links, GEP Power Products developed sealed INMIDI and INMEGA in-line fuse holders to improve protection, simplify replacement and help reduce false warranty claims.
Overload Protection for ATV Peripheral Components
It is common for all-terrain vehicles to include peripheral components such as winches and plows. Peripheral components often require electrical overload protection to help prevent motor damage caused by stalled operation or continuous-use overload conditions. In-line fuses typically protect against overloads. When an overload occurs, the fuse helps protect the connected component by interrupting the circuit before the motor burns out.
For ATV manufacturers, dependable fuse protection is especially important because vehicles are often used in demanding outdoor environments where mud, water, dirt, vibration and abrasive conditions can affect exposed electrical components.
Problems With Traditional Fusible Links
Until recently, the only type of fuse available to OEMs for protecting peripheral components against overload damage was the fusible link. Fusible links created several issues in ATV applications because they were not sealed against outdoor elements. Dirt and liquids could frequently create contact between power and ground lines, causing electrical shorts. Unsealed fusible link components could also rust, abrade or deform over time. Once corrosion or deformation occurred, replacement became more difficult after the link failed.
Common issues included:
- Exposure to dirt, moisture and outdoor contaminants
- Contact between power and ground lines
- Electrical shorts
- Rust, abrasion and deformation
- Difficult replacement after corrosion occurred
- Continued risk of component damage after fuse bypass
The Warranty Challenge for a Leading ATV Manufacturer
A leading manufacturer of all-terrain vehicles experienced repeated problems with the fusible link product installed on its equipment. The harsh environments where end users operated their equipment caused frequent shorts. In some cases, customers bypassed the links and then claimed the resulting damage as warranty items. The manufacturer also faced service challenges because the fusible link required special tools for removal. When corrosion occurred, the part became excessively difficult to replace, creating a need for a more durable, sealed and serviceable in-line fuse holder solution.
GEP’s Sealed In-Line Fuse Holder Solution
In response to the customer’s challenges, GEP designed a completely enclosed, IP67-rated sealed in-line fuse holder. The product line includes a protective, splash-proof over-molded cover designed to protect the in-line fuse from harsh environmental elements and abrasive actions.
GEP’s INMIDI and INMEGA In-Line Fuse Holders are rated from 50 to 500 amps. They are IP67 rated, meaning they are totally dustproof and tested to be completely waterproof one meter underwater for a minimum of 30 minutes.
Built for Durability and Tamper Resistance
GEP manufactures the assembly with torque-controlled tools to support consistent assembly quality. Fasteners are cemented with LOCTITE to help maintain assembly durability in demanding environments. A tamper-evident heat-shrink cover option is also available. This option helps protect against unauthorized fuse bypass by end users, which can largely reduce false warranty claims tied to bypassed protection.
Key Product Features
GEP’s INMIDI and INMEGA In-Line Fuse Holders were developed to support high-current overload protection in rugged vehicle applications. Key features include:
- 50 to 500 amp ratings: Supports a broad range of high-current protection needs.
- IP67-rated sealed construction: Protects against dust and water exposure.
- Splash-proof over-molded cover: Helps shield the fuse from harsh environmental elements and abrasion.
- Torque-controlled assembly: Supports consistent fastening during manufacturing.
- LOCTITE-cemented fasteners: Helps maintain assembly durability.
- Tamper-evident heat shrink option: Helps discourage unauthorized fuse bypass.
- Improved serviceability: Provides a sealed alternative to difficult-to-replace fusible links.
- Designed for ATV accessories: Supports overload protection for components such as winches and plows.
Power Distribution Components for Mobile Vehicles and Equipment
GEP Power Products is a RoHS-compliant and ISO 9001:2015 certified company. The company is an industry leader in electrical power distribution components for mobile vehicles and equipment. GEP offers standard and custom products for OEMs in the construction, agriculture, transportation and all-terrain vehicle industries.
