Mounting structure of strong electric components mounted on the front of the vehicle

Abstract

A mounting structure for a high-current component (1) mounted on the front of a vehicle, wherein the high-current component (1) is mounted on a crossbeam (3) of the vehicle body using an L-shaped front bracket (2f). The crossbeam (3) extends in the vehicle width direction in front of the high-current component (1). A boss (102) protrudes forward from a housing (100) of the high-current component (1). The lower vertical portion of the front bracket (2f) is fastened to the boss (102) by bolts, and the upper horizontal portion is fixed to the crossbeam (3). A fragile portion is formed at the root of the boss (102).

Description

Technical Field

[0001] The present invention relates to an installation structure for a high-voltage electrical device installed on a front section of a vehicle. Background Art

[0002] The following patent document 1 discloses a structure for mounting a strong electric component on a vehicle. A strong electric component refers to a component that handles high voltage (greater than or equal to 60V), and a special electrical system with a dedicated ground wire rather than body grounding is used for the strong electric component. Regarding this mounting structure, a bracket that integrally and horizontally protrudes from the side wall of the housing of the strong electric component is fastened to the vehicle body by bolts. In the event of a frontal collision of the vehicle, the fragile portion provided on the bracket breaks, thereby providing protection without exposing the main body of the strong electric component (the electrical component in the housing).

[0003] Patent Document 1: Japanese Patent No. 5716481 Summary of the invention

[0004] Regarding the mounting structure disclosed in Patent Document 1, the strong electric component and the fixed position to the vehicle are at the same height, so the collision load during a frontal collision works effectively and causes the bracket to break. However, when the height of the strong electric component and the height of the fixed position to the vehicle are different, a moment is generated in the bracket, and a tensile load acts on the housing of the strong electric component due to the moment. As a result, the main body of the housing may be torn, causing the electrical components in the housing to be exposed. That is, in this case, the strong electric component may not be reliably protected.

[0005] Regarding the mounting structure of the strong electric component mounted on the front of the vehicle, the feature of the present invention is to mount the strong electric component on the crossbeam of the vehicle body using an L-shaped front bracket. The crossbeam extends in the vehicle width direction in front of the strong electric component. A boss with a bolt hole formed in the center protrudes forward from the front plate of the housing of the strong electric component. The lower vertical portion of the front bracket is fastened to the boss by bolts, and the upper horizontal portion is fixed to the crossbeam. A fragile portion is formed at the root of the boss.

[0006] Effects of the Invention

[0007] According to the above-mentioned features, during a frontal collision of the vehicle, the strong electric components mounted on the front part of the vehicle can be reliably protected. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 It is a schematic perspective view showing a mounting structure according to an embodiment.

[0009] Figure 2 It is a schematic side view showing the above-mentioned mounting structure.

[0010] Figure 3 It is a perspective view showing a casing of a strong electric component (OBC unit) of the above-mentioned structure and a bracket for mounting the casing on a vehicle body.

[0011] Figure 4 It is a front view showing the boss of the above-mentioned housing to which the above-mentioned bracket is mounted.

[0012] Figure 5 yes Figure 4 VV line profile.

[0013] Figure 6 yes Figure 4 VI-VI line cross-sectional diagram.

[0014] Figure 7 It is a partial top view of the above shell.

[0015] Figure 8 It is a schematic perspective view showing the above-mentioned mounting structure at the time of a frontal collision of the vehicle. DETAILED DESCRIPTION

[0016] Below, refer to Figures 1 to 8 The mounting structure according to the embodiment is described. The strong electric component 1 is mounted on the front of the vehicle using the mounting structure. Figure 2 and Figure 8 In FIG. 1 , the front of the vehicle is indicated by an arrow FR.

[0017] like Figure 1 and Figure 2 As shown, the high-voltage component 1 involved in the mounting structure of the present embodiment is mounted in the motor room at the front of the vehicle. A high-voltage battery (not shown) is mounted on the vehicle, and the vehicle is a battery electric vehicle (BEV) that uses the power stored in the high-voltage battery to travel. The high-voltage component 1 is an OBC (On-Board Charger) unit that charges the high-voltage battery. The high-voltage component 1 is one of the high-voltage electrical devices that handle high voltage (greater than or equal to 60V). Hereinafter, the high-voltage component 1 involved in the mounting structure of the present embodiment is referred to as the OBC unit 1.

[0018] The OBC unit 1 includes an OBC 1a, a DC / DC converter 1b, and a junction box 1c. The above components are also strong electrical components. The OBC 1a includes a housing 100 (see Figure 3), the DCDC converter 1b and the junction box 1c are fixed to the housing 100. The DCDC converter 1b is fixed to the lower part of the housing 100, and the junction box 1c is fixed to the upper part of the housing 100.

[0019] An inverter 6 and a high-power motor 7 are mounted below the OBC unit 1. The above components are also high-power components. The inverter 6 and the high-power motor 7 are housed in a housing and integrated. The inverter 6 and the high-power motor 7 are mounted on a subframe, and the subframe is mounted on a longitudinal beam of the vehicle body (not shown).

[0020] The OBC unit 1 is mounted on the cross members 3 and 4 constituting the vehicle body in a suspended manner by an L-shaped bracket 2 (2f and 2r). More specifically, the housing 100 of the OBC 1a is mounted on the vehicle body by the L-shaped bracket 2 (2f and 2r), and the DCDC converter 1b and the junction box 1c are also mounted on the vehicle body via the OBC 1a.

[0021] In front of the OBC unit 1, a cross member 3 extends in the lateral direction of the vehicle. Specifically, the cross member 3 is a radiator core upper support member that supports the upper portion of the radiator core 5. On the other hand, in the rear of the OBC unit 1, a cross member 4 extends in the vehicle width direction. The OBC unit 1, that is, the housing 100 of the OBC 1a is mounted to be suspended from the cross members 3 and 4 by a pair of front brackets 2f and a pair of rear brackets 2r.

[0022] like Figure 3 As shown, two pairs of cylindrical bosses 102 protrude forward from the front plate 101 of the housing 100. A bolt hole 102a is formed at the center of each boss 102 (see Figure 4 ). In addition, reinforcing ribs 102b are formed between each pair of bosses 102. The housing 100 is made of aluminum, and the rear plate 103, the side plates, and the bottom plate 106 are also integrally formed on the basis of the front plate 101 and the bosses 102. A pair of bosses 102 are arranged longitudinally on the right side of the housing 100. Another pair of bosses 102 are arranged longitudinally on the left side of the housing 100.

[0023] In addition, Figure 3 Although the cover of the housing 100 is not shown, the cover is mounted using the screw holes 108. In addition, a pair of brackets 107 protrude forward from the upper edge of the front plate 101, and a pair of brackets 107 also protrude rearward from the upper edge of the rear plate 103. The junction box 1c is fixed to the brackets 107. A plurality of ribs 105 are also formed at intervals on the front surface of the front plate 101. The ribs 105 and the brackets 107 are also formed integrally with the housing 100.

[0024] The lower vertical portion of the front bracket 2f is fastened to the above-mentioned pairs of bosses 102 by bolts 202. Flanges are formed on both side edges of the front bracket 2f to improve rigidity and strength. The front bracket 2f is a steel angle bar. A pair of bolt insertion holes 200 for inserting the bolts 202 are formed in the lower vertical portion of the front bracket 2f. The bolts 202 are fastened to the above-mentioned bolt holes 102a. On the other hand, bolt insertion holes 201 are also formed in the upper horizontal portion of the front bracket 2f. The upper horizontal portion of the front bracket 2f is fixed to the crossbeam 3 through the bolt insertion holes 201.

[0025] A vulnerable portion is formed at the base of the lower boss 102 of each pair of two bosses 102. When the front of the vehicle collides, the vulnerable portion breaks when the front bracket 2f moves rearward relative to the housing 100, thereby preventing the main body of the housing 100 from being damaged. Thus, it is possible to prevent the electrical components in the housing 100 from being exposed, and the OBC 1a, that is, the OBC unit 1, can be reliably protected. Specifically, the vulnerable portion of this embodiment is composed of the following structures [1] and [2].

[0026] [1] Figures 4 to 6 As shown, the lower boss 102 protrudes forward from the base portion 109 integrally formed on the front plate 101. In addition, the thickness t1 of the root (fragile portion) of the boss 102 in the direction perpendicular to the axis O of the bolt hole 102a is smaller than the thickness t2 of the base portion 109 in this direction. In addition, the thickness of the base portion 109 is not uniform over the entire circumference of the boss 102, so here it is compared with the thickness t2 of the weakest and thinnest lower portion. In addition, in this embodiment, the upper boss 102 also protrudes forward from the base portion 109.

[0027] In this embodiment, if Figure 5 As shown in FIG. 1 , the width of the upper portion of the base portion 109 in the front-to-back direction is greater than the width of the lower portion of the base portion 109 in the front-to-back direction. That is, the surface of the base portion 109 is inclined. Therefore, when a tensile force to pull out the bolt 202 acts on the lower boss 102, the lower portion of the base portion 109 is more able to resist the tensile force than the upper portion of the base portion 109. The tensile force acts when the vehicle is hit from the front, which will be described later. In addition, regarding the rib 105, the width of the upper portion in the front-to-back direction is also greater than the width of the lower portion in the front-to-back direction.

[0028] The thickness t1 of the boss 102 is smaller than the thickness t2 of the base 109. Therefore, if the tensile force acts on the boss 102, the fragile portion at the base of the boss 102 breaks, which can prevent the main body of the housing 100 including the front plate 101 formed with the base 109 from being damaged. Thus, the interior of the housing 100 can be prevented from being exposed.

[0029] [2] And, Figure 6 As shown, the curvature radius R1 of the rising edge of the root of the boss 102, which is the fragile portion, starting from the base portion 109 is smaller than the curvature radius R2 of the rising edge of the base portion 109 starting from the front plate 101. Therefore, if the above-mentioned tensile force acts on the boss 102, more stress is concentrated on the fragile portion of the root of the boss 102. Therefore, the fragile portion of the root of the boss 102 is more likely to break.

[0030] In addition, in the present embodiment, the mounting structure of the front side of the OBC unit 1 is also symmetrically configured on the rear side of the OBC unit 1. That is, two pairs of cylindrical bosses 104 integrally protrude from the rear plate 103 of the housing 100 toward the rear. One pair of bosses 104 is arranged longitudinally on the right side of the housing 100, and the other pair of bosses 104 is arranged longitudinally on the left side of the housing 100. Moreover, the lower vertical portion of the rear bracket 2r is fastened to each pair of bosses 104 by bolts, and the upper horizontal portion of the rear bracket 2r is fixed to the crossbeam 4. The above-mentioned fragile portion is formed on the lower side of each pair of bosses 104.

[0031] Reference Figure 8 The effect of the pulling force on the lower boss 102 during a frontal collision of the vehicle will be described. As described above, the OBC unit 1 is mounted on the cross members 3 and 4 in a manner suspended by the L-shaped brackets 2 (2f and 2r). During a frontal collision of the vehicle, the front end of the vehicle is crushed and moves backward relative to the vehicle body. Along with this, the cross member as the upper support member of the radiator core is pressed toward the OBC unit 1.

[0032] At this time, the collision load F is as follows Figure 8 As shown by the arrow F in FIG. 1 , the upper horizontal portion of the front bracket 2f is relatively moved rearward via the cross beam 3. As a result, a compressive force acts on the upper boss 102, and as shown in FIG. Figure 8 As shown by the arrow Ft in the figure, due to the lever principle, the tension Ft for pulling out the bolt 202 acts on the lower boss 102. The boss 102 is broken at the weak part, that is, the root thereof, by the tension Ft acting on the lower boss 102. The boss 102 is broken to prevent the main body of the housing 100, that is, the front plate 101, from being damaged. As a result, the electrical components in the housing 100 are not exposed.

[0033] Here, in this embodiment, and, as Figure 5 to Figure 7As shown, the thickness of the bottom plate 106 on the opposite side of the boss 102 is locally thickened relative to the front plate 101 to form a thick plate portion 106a. That is, the thickness of the thick plate portion 106a is thicker than the thickness of the bottom plate 106 other than the thick plate portion 106a. Not only is the front plate 101 reinforced by the base portion 109, but the bottom plate 106 is also partially reinforced by the thick plate portion 106a, so that the main body of the housing 100 can more effectively resist the above-mentioned tensile force Ft. As a result, damage to the main body of the housing 100, such as peeling of the front plate 101 from the bottom plate 106, can be prevented.

[0034] In addition, as described above, in this embodiment, the mounting structure is also configured symmetrically on the rear side of the OBC unit 1. Figure 8 In the state shown, when the OBC unit 1 moves rearward relative to the vehicle body, a tensile force acts on the lower boss 104 at the rear side of the housing 100. Therefore, the fragile portion of the lower boss 104 can be prevented from breaking, and the main body of the housing 100, that is, the rear plate 103 can be prevented from being damaged. As a result, the electrical components in the housing 100 are not exposed.

[0035] As described above, the mounting structure involved in this embodiment includes: a boss 102, which protrudes forward from the front plate 101 of the shell 100 of the strong electric component 1; a cross beam 3, which extends in the vehicle width direction in front of the strong electric component 1; and an L-shaped front bracket 2f. The lower vertical portion of the front bracket 2f is fastened to the bolt hole 102a of the boss 102 by the bolt 202, and the upper horizontal portion is fixed to the cross beam 3. Moreover, a fragile portion is formed at the root of the (lower side) boss 102. Therefore, when the vehicle collides from the front, the fragile portion formed at the root of the boss 102 breaks, thereby preventing the main body of the shell 100 from being damaged and reliably protecting the strong electric component 1.

[0036] Regarding the above-mentioned fragile portion, the boss 102 protrudes forward from the base portion 109 formed on the front plate 101. In addition, the thickness t1 of the root portion of the boss 102 in the direction perpendicular to the axis O of the bolt hole 102a is smaller than the thickness t2 of the base portion 109 in the direction. Therefore, the boss 102 can be reliably broken at the fragile portion of the root portion of the boss 102.

[0037] In addition, regarding the fragile portion, the curvature radius R1 of the rising edge of the base portion 109 of the boss 102 is smaller than the curvature radius R2 of the rising edge of the base portion 109 from the front plate 101. Therefore, the boss 102 can be more reliably broken at the fragile portion of the boss 102.

[0038] In addition, the thickness of the bottom plate 106 on the opposite side of the boss 102 is partially thicker than that of the front plate 101 to form a thick plate portion 106a. Therefore, damage to the housing 100 can be more reliably prevented.

[0039] In addition, the present invention is not limited to the above-mentioned embodiment. For example, in the above-mentioned embodiment, two bosses 102 (104) are arranged in the vertical direction to form a pair. However, only one boss 102 may be provided at each pair. In this case, the L-shaped front bracket 2f (rear bracket 2r) is also used to make the tension act on the boss 102 (104), so that the housing 100 can be prevented from being damaged.

[0040] Description of the label

[0041] 1 OBC unit (strong current component)

[0042] 1a OBC (strong current components)

[0043] 2 Bracket

[0044] 2f Front bracket

[0045] 2r Rear bracket

[0046] 3, 4 beams

[0047] 100 (Housing of high-voltage components 1, 1a)

[0048] 101 front panel

[0049] 102 Boss

[0050] 102a Bolt hole

[0051] 106 Base Plate

[0052] 106a thick plate part

[0053] 109 Base

[0054] O Axis (of bolt hole 102a)

[0055] t1 (thickness of boss 102)

[0056] t2 (thickness of the base 109)

[0057] R1 (the curvature radius of the rising edge of the boss 102)

[0058] R2 (radius of curvature of the base portion 109)

Claims

1. A mounting structure for a strong electric component mounted on the front of a vehicle, The mounting structure has: The strong electric components; A boss, which is integrally formed with a front plate of the housing of the strong electric component and protrudes forward from the front plate, and has a bolt hole formed in the center; A cross beam extending in the vehicle width direction in front of the strong electric component and constituting the vehicle body; and The L-shaped front bracket has a lower vertical portion fastened to the boss by bolts, and an upper horizontal portion fixed to the crossbeam. A fragile portion is formed at a portion where the boss is connected to the front plate, that is, at a root of the boss.

2. The mounting structure according to claim 1, wherein: The boss protrudes forward from a base portion formed on the front plate, The thickness of the fragile portion of the boss in a direction perpendicular to the axis of the bolt hole is smaller than the thickness of the base portion in the direction.

3. The mounting structure according to claim 2, wherein: The curvature radius of the rising edge of the root portion as the fragile portion starting from the base portion is smaller than the curvature radius of the rising edge of the base portion starting from the front plate.

4. The mounting structure according to any one of claims 1 to 3, wherein: The thickness of the bottom plate of the housing on the opposite side of the boss of the front plate is partially thickened.

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