Enclosure for electrical components of a motor vehicle.
Patent Information
- Application Number
- FR2021002630
- Authority / Receiving Office
- FR · FR
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2021-03-16
- Publication Date
- 2025-03-14
- Estimated Expiration
- 2041-03-16
Smart Images
Figure 00000021_0000 
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Abstract
Description
Title of the invention: Housing for electrical components of a motor vehicle.
[0001] The invention relates to a housing for electrical components of a motor vehicle. The invention also relates to an electrical pack comprising such a housing. The invention further relates to a method for assembling such an electrical pack. The invention also relates to a motor vehicle equipped with such an electrical pack. The invention further relates to a method for assembling such a motor vehicle.
[0002] Reducing the carbon footprint of vehicles is a major focus of technological innovation, particularly in the automotive industry.
[0003] Some of these innovations require the addition of a 48-volt battery in internal combustion engine vehicles. This 48-volt battery is designed to power various electrical equipment that reduces carbon emissions. In particular, in some vehicles, the 48-volt battery powers a heating element to improve the performance of the catalytic converter. In addition, or alternatively, the 48-volt battery can also power a small electric motor, also called a starter-alternator, designed to assist the internal combustion engine during specific driving phases, notably when restarting the vehicle during the operation of the Stop and Start function. Conversely, the starter-alternator, in turn, charges the 48-volt battery during driving phases.
[0004] Adding a 48-volt battery necessitates the addition of various components associated with its use to the engine compartment. However, integrating these new components into a pre-existing vehicle structure presents spatial constraints. These constraints relate not only to the available space for housing the components, but also to the routing of the new hoses and cables required for them.
[0005] The object of the invention is to provide a device to overcome the constraints described above. In particular, the invention makes it possible to create a device that is simple and reliable and that allows for compact installation and optimal connection of new electrical components in the engine compartment.
[0006] To this end, the invention relates to a housing for electrical components of a motor vehicle constituting a support for at least two or at least three electrical components, in particular at least two or at least three components from among: - a first 48V-12V voltage converter, - a second 48V-12V voltage converter, - an engine control unit, - a calculator for a heated grill, - a 12V battery safety module, and - an electrical terminal block, the case also includes: - elements for attaching electrical components to the housing, and - elements for attaching the housing to a mounting structure of a motor vehicle.
[0007] The dimensions of the housing may allow it to fit into a space intended for a 12V L3 type electric battery and / or the housing may be intended to be installed in an engine compartment of a motor vehicle.
[0008] The housing may include: - a first part comprising five substantially flat faces constituting respectively a base, of substantially rectangular shape, and four lateral walls fixed perpendicularly to the base, and - a lid fitting onto the first part, the lid having a main face, notably of a shape substantially identical to the base, and, - a housing fixed to the top of the main face of the lid, the housing comprising a base and a lid.
[0009] A first side wall may have an opening for connecting electrical components to an electrical connector and a second side wall may have an opening for connecting electrical components to a cooling circuit.
[0010] The housing may include arrangements allowing the electrical components to be placed at least substantially parallel to each other.
[0011] The arrangements can be configured so that the components are arranged: - horizontally, or - at an acute angle greater than or equal to 8° with respect to the horizontal, or - vertically or almost vertically.
[0012] The invention also relates to an electrical pack comprising a housing for electrical components according to the invention and at least two components or at least three of the following: - a first electrical voltage converter from 48 Volts to 12 Volts, - a second 48 Volt-12 Volt voltage converter, - an engine control unit, - a calculator for a heated grill, - a 12-volt battery safety element, and - an electrical terminal block.
[0013] The invention further relates to a method for assembling an electrical pack according to the invention, comprising the following steps: - at least a first step of mounting a first electrical component in the housing, and - at least one second step of mounting a second electrical component in the housing, for example: - the first step of installing the engine control unit (ECU) on the base of the housing, - a second stage of installing a first converter above the engine control unit, - a third step of placing a plate above the first converter, - a fourth step of placing the second converter above the plate, - a fifth step of fitting the housing cover onto the first part of the housing, - a sixth step of installing the electrical terminal block in the base of the housing, - a seventh step of fitting the housing cover onto the housing base, - an eighth step involving the installation of a heating grid calculator on the housing cover, and - a ninth step of fixing a safety element to the plate, the steps of installing a component including at least one assembly of the component to the housing.
[0014] The invention further relates to a motor vehicle comprising, in particular comprising in an engine compartment, an electric pack according to the invention.
[0015] The invention also relates to a method for assembling a motor vehicle, in particular a motor vehicle according to the invention, the vehicle comprising at least one hydraulic cooling duct, one air duct, electrical wiring and a mounting structure, the method comprising: - a first step of attaching a housing to the mounting structure, - a second step of implementing the assembly process according to the invention, - a third step of connecting at least one hydraulic cooling duct to the electrical pack, in particular to electrical converters, - a fourth step of attaching the air duct to the electrical pack, - a fifth step of connecting all the electrical components to the electrical wiring.
[0016] The attached drawing represents, by way of example, an embodiment of a housing for electrical components according to the invention.
[0017] [Fig-1] Fig. 1 schematically represents a motor vehicle equipped with a housing for electrical components according to one embodiment.
[0018] [Fig.2] The [Fig.2] is a perspective view of a first part of a housing for electrical components according to an embodiment of the invention.
[0019] [Fig.3] The [Fig.3] is a cross-sectional view of the first part of a housing for electrical components according to the embodiment of the invention.
[0020] [Fig.4] The [Fig.4] is a perspective view of a plate of a housing for electrical components according to the embodiment of the invention.
[0021] [Fig.5] The [Fig.5] is a perspective view of a cover of a housing for electrical components according to the embodiment of the invention.
[0022] [Fig.6] The [Fig.6] is a perspective view of a cover for housing a case for electrical components according to the embodiment of the invention.
[0023] [Fig.7] The [Fig.7] is a flowchart of a method for assembling an electrical pack according to an execution method.
[0024] [Fig.8] Fig.8 illustrates the first step of the process of assembling an electrical pack according to the embodiment.
[0025] [Fig.9] Fig.9 illustrates the second step of the process of assembling an electrical pack according to the embodiment.
[0026] [Fig. 10] The [Fig. 10] illustrates the third step of the process of assembling an electrical pack according to the embodiment.
[0027] [Fig. 11] The [Fig. 11] illustrates the fourth step of the process of assembling an electrical pack according to the embodiment.
[0028] [Fig. 12] The [Fig. 12] illustrates the fifth step of the process of assembling an electrical pack according to the embodiment.
[0029] [Fig. 13] The [Fig. 13] illustrates the sixth and seventh steps of the process of assembling an electrical pack according to the embodiment.
[0030] [Fig. 14] The [Fig. 14] illustrates the eighth step of the process of assembling an electrical pack according to the embodiment.
[0031] [Fig. 15] The [Fig. 15] illustrates the ninth step of the process of assembling an electrical pack according to the embodiment.
[0032] [Fig. 16] The [Fig. 16] is a flowchart of a method for assembling a vehicle according to an execution method.
[0033] [Fig. 17] The [Fig. 17] is a first perspective view of the connections of a vehicle according to the embodiment of the invention.
[0034] [Fig. 18] The [Fig. 18] is a second perspective view of the connections of a vehicle according to the embodiment of the invention.
[0035] [Fig. 19] The [Fig. 19] is a third perspective view of the connections of a vehicle according to the embodiment of the invention.
[0036] An embodiment of a motor vehicle 100 is described below with reference to [Fig. 1]. The motor vehicle 100 is a motor vehicle of any type, in particular a passenger vehicle or a commercial vehicle.
[0037] The motor vehicle 100 is equipped with an engine block comprising a thermal engine 40. The thermal engine may be of any type, including gasoline or diesel. In one embodiment, the engine block could further comprise an electric motor 50, in particular a starter-alternator 50 to enable the implementation of a mild hybrid system.
[0038] Associated with the internal combustion engine 40, the motor vehicle 100 also includes a first electrical component or computer, called the engine computer 2, which controls the operation of the internal combustion engine.
[0039] The motor vehicle 100 also includes an exhaust line equipped with a heating grid 70 to optimize the efficiency of the after-combustion treatment implemented in the vehicle.
[0040] Associated with the heating grid 70, the motor vehicle 100 also includes a second electrical component or computer, called the heating grid computer 3, which controls the operation of the heating grid.
[0041] The motor vehicle 100 is equipped with a first battery 20 providing a voltage of 48 Volts intended in particular for the electrical supply of the heating grid 70, and possibly an electric motor 50.
[0042] Since the 48-volt battery can generate excess current, advantageously the motor vehicle 100 can also be equipped with a third electrical component to convert a voltage of 48 volts into a voltage of 12 volts. The third electrical component is also called the first converter 4.
[0043] The motor vehicle 100 is also equipped with a second battery 30 providing a voltage of 12 volts, intended in particular for powering the electrical and electronic equipment of the motor vehicle 100. The second battery 30 is connected to a fourth electrical component, called the safety module 7, containing fuses. These fuses protect the power supply circuits that connect the second battery 30 to the electrical and electronic equipment it powers.
[0044] The motor vehicle 100, particularly when it is a commercial vehicle, may include one or more additional pieces of equipment 60, specific to the area of use of the commercial vehicle. This additional equipment is generally powered by a 12-volt supply. For example, the vehicle 100 may include refrigerators or other equipment consuming a significant amount of 12 volts.
[0045] Advantageously, the motor vehicle 100 can include a fifth electrical component, called a second converter 5, which provides a significant amount of 12 Volt voltage, by transforming a significant surplus of 48 Volt voltage.
[0046] The motor vehicle 100 can be equipped with a hydraulic cooling means 80 connected to at least one hydraulic cooling conduit 801.
[0047] The motor vehicle 100 can also be equipped with an air cooling means 90 connected to an air duct 901.
[0048] The first, second, third, fourth and fifth electrical components 2, 3, 4, 5, 7 are arranged in a housing 1 according to the invention.
[0049] In order to organize the distribution of electrical current in the electrical components of the housing, a sixth electrical component, or bomier 6, is advantageously arranged in the housing 1.
[0050] The arrangement of the six electrical components 2, 3, 4, 5, 6, 7 in the housing 1 constitutes an electrical pack 10. One of the roles of the electrical pack, and more particularly of the housing 1, is to optimize the space required for the installation of the six electrical components 2, 3, 4, 5, 6, 7.
[0051] Advantageously, the electrical pack 10 is intended to be installed in the engine compartment of a motor vehicle. In the preferred embodiment described below, the reduced dimensions of the electrical pack 10, and more particularly of the housing 1, allow it to fit into a space equivalent to that traditionally provided for housing a 12V L3 type electric battery, notably in the engine compartment. In other words, in this embodiment, the volume of the electrical pack 10 is such that it can fit into a rectangular parallelepiped defined by the following dimensions: 261.7 mm x 282.6 mm x 350 mm.
[0052] The motor vehicle 100 further comprises a mounting structure 110 adapted to receive the electrical pack 10, in particular adapted to be attached to the housing 1. The mounting structure 110 may, for example, be a bracket initially intended for a 12-volt battery tray. The mounting structure 110 could also be the side member of the vehicle 100. In a preferred embodiment, the structure 110 comprises a substantially horizontal surface intended to be in contact with the lower surface of the housing 1.
[0053] The various electrical components of the housing are supplied, via 600 connections, either with 48 Volt direct current or with 12 Volt direct current.
[0054] With regard to the 12 Volt DC power supply, two power supply circuits are distinguished: - a first 12 Volt power supply circuit is connected to converters 4, 5 via terminal block 6 of electrical pack 10, the 12 Volt current being generated by converters 4, 5, - and a second 12 Volt power supply circuit is connected to the 12 Volt battery via an interconnection box 35 called the "engine interconnection box", external to the electrical pack 10.
[0055] The first circuit relates exclusively to the power supply of the additional equipment 60. It uses the 12 Volt current generated by the converters 4, 5 to power the additional equipment 60 via the terminal block 6.
[0056] Via the interconnection box 35, the second circuit connects the 12-volt battery 30 and the safety element 7 to the vehicle components 100 – other than the additional equipment 60 – which are powered by 12 volts. In particular, the engine control unit 2 is connected, via a connection 600, to the engine interconnection box 35.
[0057] In addition, the second circuit advantageously includes connections 600 linking the converters 4, 5 to the interconnection box 35, in particular for recharging the battery 30.
[0058] Regarding the 48 Volt supply, in a preferred embodiment, terminal block 6 constitutes the sole input point of the 48 Volt DC current into the electrical pack 10. For this purpose, terminal block 6 is supplied by a 48 Volt DC signal via a connection 600 to the battery 20.
[0059] In this embodiment, terminal block 6 also constitutes the sole output point of the 48-volt DC current to equipment external to the electrical pack 10 using a 48-volt DC signal. In other words, the circuits 600 supplying the electric motor 50, the control unit for the heating grid 3, and the heating grid 70 are connected to terminal block 6.
[0060] In addition, internal to the electrical pack 10, other circuits 600 connect the terminal block 6 to the converters 4, 5 for their supply by a continuous signal of 48 Volts.
[0061] An embodiment of the housing 1 is described below with reference to figures 2 to 5.
[0062] In the described embodiment, the housing 1 comprises a first part 11, plus particularly represented in figures 2 and 3, presenting five faces A, B, C, D, E substantially flat constituting respectively a base E, of substantially rectangular shape, and four lateral walls A, B, C, D fixed perpendicularly to the base E.
[0063] In a preferred embodiment, the base E of the housing has a length of approximately 283 mm (corresponding to the width of faces B and D, although the width of faces B and D may vary depending on the height) and a width of approximately 262 mm (corresponding to the width of faces A and C, the width of faces A and C may however vary depending on the height).
[0064] In the embodiment presented, faces B and D are in the shape of a right trapezoid, their upper side being inclined with respect to a plane containing the base E. The heights of faces A, B, C and D are preferably between 220 mm and 260 mm.
[0065] Optionally the housing 1 also includes a 45-degree chamfer disposed on the angle formed by the two contiguous side walls A, B.
[0066] The side walls A, B, C, D have main openings or notches through which at least one electrical, hydraulic or air connection can extend.
[0067] The wall A has in particular two notches Al, A2 and an opening allowing to connect at least one hydraulic cooling conduit 801 to the first and second converters 4, 5. In one embodiment, the notches Al, A2 each have approximately a height of 42 mm and a width of 52 mm for Al and 47 mm for A2.
[0068] Optionally, wall A also has an opening (not shown in the figures) for connection to an air duct 901, this connection being made directly on the housing 1.
[0069] In addition or alternatively, wall B also has an opening which extends over a large part of its height in order to provide an opening for the connection of the engine control unit 2. In particular, the opening of wall B can extend over approximately 232 mm in height and between 170 and 190 mm in width.
[0070] In addition or alternatively, wall C also has an opening in its upper part to allow the fixing of the safety element 7. In particular, the opening of wall C can extend over approximately 58 mm in height and 205 mm in width.
[0071] In addition or alternatively, wall D also has an opening in its upper part to allow the connection of converters 4, 5. In particular, the opening of wall D can extend over approximately 157 to 181 mm in height and 185 mm in width.
[0072] Thus, in the embodiment presented, each of the walls A, B, C, and D consists, in its upper part, of two narrow uprights framing a wide opening. These narrow uprights, on two adjacent faces, form, in pairs, right angles BC, CD, and DA. Since the angle formed by walls A and B is chamfered, walls A and B have, in their upper part, a common upright AB corresponding to the chamfer. As a side note, the chamfer serves to optimize the overall dimensions of the housing 1, particularly in relation to the environment in which the housing is intended to be inserted. In other embodiments, this chamfer might not be necessary.
[0073] Housing 1 comprises: - fixing elements for electrical components 2, 3, 4, 5, 6, 7 to housing 1, and - fixing elements for housing 1 to the fixing structure 110 of the motor vehicle 100.
[0074] The fasteners are described below. In the remainder of this document, the terms "fasteners", "bearing surface" or "fixing surface" are used interchangeably to refer to a fastener. A fastener may be, for example, a surface, such as a bearing surface, or a hole in a surface, through which a fastener extends.
[0075] The base E of the housing is generally continuous over its entire surface, that is to say, approximately solid, in that there is no opening or notch for a connection, as is the case with at least one of the side walls. It has three fixing elements, in particular three openings E1, E2, E3 for the passage of screws fixing the first element of the housing to the vehicle mounting structure 110 100.
[0076] In addition, the base E and the side walls A and C of the first part 11 provide fixing elements, in particular support surfaces for the positioning and fixing of the engine control unit 2 and the first current converter 4.
[0077] For this purpose, the base E also includes two shoulders E4, E5 whose surface is contained in a first support plane PL. The support plane PI is inclined at an angle α with respect to the support surface of the base E.
[0078] Shoulders E4, E5 will provide fixing elements for mounting the engine control unit 2.
[0079] The side walls A and C, arranged opposite each other, respectively provide fixing elements comprising bearing surfaces A5, C4 which are contained in a second bearing plane P2, parallel to PL. The bearing surfaces A5, C4 will serve as a support and fixing support for the first converter 4.
[0080] The side walls A and C also provide fixing elements comprising bearing surfaces for fixing a plate 8 disposed between the first converter 4 and the second converter 5. The side face A provides two fixing surfaces, A6 and A7, and the side face C provides a fixing element C5.
[0081] Thanks to these fixing elements, the plate 8 is arranged according to a third fixing plane P3 parallel to the first two fixing planes, PI, P2.
[0082] Plate 8 is more specifically described in [Fig. 4]. The surface of plate 8 is distributed along mainly two planes, a lower plane and an upper plane. The The lower plane comprises the first, second and third elements 81, 82, and 83 of the plate 8, which are surfaces intended to be fixed to the fixing elements A6, A7, C5. In other words, after fixing, the lower plane of the plate 8 will be arranged in the third plane P3.
[0083] Furthermore, in its upper plane, the plate 8 provides fixing elements 84, 85 intended for fixing the second converter 5 in a fixing plane P4 parallel to the other fixing planes PI, P2, and P3.
[0084] In one embodiment, the plate 8 further provides a fixing element 86 for fixing the safety element 7 of the 12 Volt battery.
[0085] In addition to the first part 11, the housing 1 according to the invention includes a cover 12 (represented by [Fig.5]) fitting onto the first part 11, the cover having a main face F, in particular of substantially identical shape to the base E.
[0086] The cover 12 is designed to fit onto the upper ends of the uprights AB, BC, CD, DA described above. Advantageously, the upper ends of the uprights AB, BC, CD, DA have been dimensioned so as to lie in the same fixing plane P5, parallel to the other fixing planes. Thus, the cover 12 is also inclined at an angle α with respect to the bearing surface of the base E. The top of the main face F of the cover is therefore located in a fixing plane P6 parallel to the other fixing planes, the distance between planes P5 and P6 corresponding to the thickness of the cover.
[0087] Advantageously, the cover 12 includes a rectangular recess 121, located on the lateral edge intended to fit onto the lateral face D of the first part 11 of the housing.
[0088] A housing 13 is fixed to the top of the main face F of the cover 12. The housing comprises a two-part base 131, 132 and a cover 133 that fits onto the two parts 131, 132 of the base. The two parts 131, 132 of the base are shaped like hooks or crenellations placed opposite each other, so as to define a frame. An electronic component, in particular the terminal block 6, can be placed on the cover 12 inside this frame. Advantageously, the dimensions of the frame are adapted to the dimensions of the terminal block 6 so as to limit the play between the terminal block and the frame. The cover 133, shown in [Fig. 6], can be fitted onto the frame to close the space defined by the frame. The base 131, 132 and the cover 133 together form a fixing element for an electrical component in the housing 1, in particular a fixing element for the terminal block 6.
[0089] The height of the two parts 131, 132 of the base is defined so as to position the cover of the housing 133 in a plane P7 parallel to P6. The cover 133 further includes a fastening element 134 on its upper surface, the fastening element being intended for the heating grid's control unit 3. In a mode of The fixing element comprises four screws or four fixing pins intended to be inserted into eyelets of the calculator 3.
[0090] Thus, in the described embodiment, the housing 1, associated with the plate 8, provides elements E4, E5, A3, A4, A5, A6, C2, C3, C4, C5, 81, 82, 83, 84, 85, 86, AB, BC, CD, DA, 131, 132, 133, 134 for fixing the electrical components 2, 3, 4, 5, 6, 7 to the housing 1. Furthermore, the housing 1 provides elements E1, E2, E3 for fixing to the fixing structure 110 of the motor vehicle 100.
[0091] Thus, in the preferred embodiment described above, the housing and the fastening elements provided by the housing are designed to arrange the electrical components 2, 3, 4, 5, 6 one above the other, in planes P1, P2, P4, P5, P6, P7 that are substantially parallel to each other and each form an angle α with the lower surface of the housing 1. The lower surface of the housing 1 is itself arranged in a substantially horizontal plane by means of the mounting structure 110 of the motor vehicle 100. As a result, the electrical components 2, 3, 4, 5, 6 are inclined with respect to a horizontal plane, in particular at an angle substantially equal to α. According to regulations concerning the electrical equipment of a motor vehicle, to prevent water from stagnating on the surface of the electrical equipment, the angle α must be greater than or equal to 8 degrees.
[0092] In an alternative embodiment, the electrical components could be arranged in a different orientation, for example, vertical or substantially vertical. Such an embodiment could be advantageous in situations where the height of the enclosure is limited. In particular, such an embodiment could be preferable when the space available for installing the electrical pack in the vehicle 100 is less than its other dimensions, especially its width and / or depth.
[0093] An embodiment of a method for assembling an electrical pack 10 according to the invention is described below with reference to [Fig. 7]. The described embodiment corresponds to the preferred embodiment of the electrical pack, that is to say, the embodiment where the electrical components are arranged one above the other.
[0094] The method for assembling an electrical pack comprises nine steps, E1 to E19, which are carried out successively.
[0095] A first step El 1 of assembling pack 10 is illustrated in [Fig. 8]. The first step Eli is a step of positioning the engine control unit 2 on the base E of the housing 1. The engine control unit 2 is positioned resting on the mounting elements E4, E5, these mounting elements (more specifically visible in Figures 2, 3 and 8) being formed by two shoulders on the base E of the housing 1. The engine control unit 2 is then fixed by screws to the mounting elements E4, E5, by means of mounting tabs present on the control unit 2. Recesses A3, A4, C2, and C3 are made on the lateral faces A and C to provide passage for the mounting lugs of the engine control unit (ECU) 2. The ECU 2 is positioned so that its connector face faces face B of the first element 11 of the housing 1. The connector face of ECU 2 has fins for mechanically locking the ECU 2 to the associated electrical circuit. Advantageously, face B is widely open to allow this mechanical locking to be performed after the ECU has been installed in the housing 1.
[0096] A second assembly step E12 is illustrated in [Fig. 9]. The second step E12 is a step of positioning the first converter 4 above the engine control unit 2. The first converter 4 is positioned resting on the mounting elements A5 and C4 provided respectively by the side faces A and C. The first converter 4 includes three mounting lugs for its attachment by screws to the mounting elements A5 and C4. In an alternative embodiment, the first converter 4 could include a different number of mounting elements; in this case, the housing 1 would then be adapted to provide the appropriate mounting elements.
[0097] Furthermore, on the first lateral face, the first converter 4 has connection fittings intended for connection to a hydraulic conduit 801. The connection fittings of the first converter 4 are advantageously arranged in openings Al, A2 made on the lateral face A.
[0098] In addition, on a second side face, the first converter 4 has an electrical connection socket intended for a connection 600 of the first converter 4 to the terminal block 6. The connection socket of the first converter 4 is advantageously positioned opposite a large opening made on the side face D.
[0099] A third assembly step E13 is illustrated in [Fig. 10]. The third step E13 is a step of positioning the plate 8 above the first converter 4. In this step, the mounting plate 8 is positioned to rest on the mounting elements A6, A7 and C5 provided respectively by the side faces A and C. A screw fixing is made between the first, second and third elements 81, 82, 83 of the plate 8 and the mounting elements A6, A7 and C5 of the side faces A and C of the housing 1.
[0100] A fourth assembly step E14 is illustrated in [Fig. 11]. The fourth step E14 is a step for positioning the second converter 5 on top of the plate 8. The second converter 5 rests on the fastening elements 84 and 85 provided by the upper surface of the plate 8. The second converter 5 includes three fastening lugs for securing it with screws advantageously arranged on the fastening elements 84 and 85. Thus, the first and second converters 4, 5 are positioned respectively in planes P3 and P5, and separated from each other by the plate 8. In particular, due to its geometry, the plate 8 maintains a free space between plans P3 and P5, this free space allowing better ventilation and better cooling of converters 4, 5.
[0101] Furthermore, on the first side face, the second converter 5 has connection fittings intended for connection to a hydraulic conduit 801. The connection fittings of the second converter 5 are advantageously arranged in a wide opening made on the side face A.
[0102] In addition, on a second side face, the second converter 5 has an electrical connection socket intended for a connection 600 of the second converter 5 to the terminal block 6. The connection socket of the second converter 5 is advantageously positioned opposite the wide opening made on the side face D.
[0103] A fifth assembly step E15 is illustrated in [Fig. 12]. The fifth step E15 is a step of fitting the cover 12 of the housing 1 onto the first part 11 of the housing 1. The cover 12 of the housing rests on the upper part of the uprights AB, BC, CD, DA of the first part of the housing 1. The cover 12 can be fixed by clipping and / or held by screws onto the first part 11 of the housing. The recess 121 of the cover is advantageously positioned above the side face D of the housing, so as to facilitate the passage of the electrical connection 600 of the second converter 5.
[0104] A sixth step E16 and a seventh step E17 of assembly are illustrated by [Fig. 13]. The sixth step E16 is a step of placing the electrical terminal block 6 in the base 131, 132 of the housing 13 arranged on the cover 12 of the housing.
[0105] Advantageously, the side face of the terminal block 6, which is oriented towards the side face D of the housing, provides connections for the elements connected to the 48 Volt circuit, in particular for the 48 Volt battery 20, the converters 4, 5, the electric motor 50, the control unit for the heating grid 2 and the heating grid 70. In addition or alternatively, it also provides connections for the additional equipment 60 supplied with 12 Volts from the current supplied by the converters 4, 5.
[0106] The seventh step E17 is a step of fitting the cover 133 of the housing 13 onto the base 131, 132 of the housing 13. The cover 133 of the housing 13 is thus positioned above the frame formed by the base 131, 132, for fixing the terminal block 6 in the housing 13. The cover 133 can be fixed to the base 131, 132 by screws.
[0107] An eighth assembly step E18 is illustrated in [Fig. 14]. The eighth step E18 is a step of mounting a heating grid control unit 3 onto the cover 133 of the housing 13. In the embodiment shown in [Fig. 12], the heating grid control unit has four screw holes on its lateral edges. The fixing element 134 of the cover 133 has four lugs advantageously arranged opposite the screw holes of the control unit. Calculator 3 is thus fixed by screws to cover 133. Advantageously, the connector of calculator 3 is oriented towards the side face D of the housing.
[0108] A ninth assembly step E19 is illustrated in [Fig. 15]. The ninth step E19 is a step of attaching the safety element 7 to the plate 8, in particular via the fastening element 86. The connection between the safety element 7 and the fastening element 86 is made by a screw and a nut. In this embodiment, the safety element 7 is positioned along the lateral face C of the housing. Note that when the assembly is carried out after the housing 1 has been attached to the vehicle 100, the step of attaching the safety element is preferably carried out after the assembly of the two converters 4, 5, i.e., between steps E14 and E15.
[0109] In an alternative embodiment, steps E16, E17 and E18 of mounting the electrical components 6 and 3 on the cover of the housing could be carried out before step E15 of mounting the cover 12 on the first part 11 of the housing 1.
[0110] An embodiment of a method for assembling a vehicle according to the invention is described below with reference to [Fig. 16].
[0111] The assembly of the vehicle 100 preferably begins with a first step E21 of attaching the first part 11 of the housing to the mounting structure 110 of the vehicle 100. For this purpose, screws can, for example, be inserted into the fastening elements E1, E2, E3 of the base E of the housing (these fastening elements being more specifically shown in [Fig. 2]). The screws are then fastened to the mounting structure 110 by nuts (one embodiment of the mounting structure 110 being illustrated in [Fig. 18]).
[0112] The housing 1 is mounted in the motor vehicle so that the lateral face C of the housing, intended to receive the safety element 7, is oriented towards the vehicle's bulkhead, i.e., towards the rear end of the vehicle. Advantageously, the mounting of the housing 1 allows for a free space around the lateral face C, thus preserving a free space around the safety element 7 when it is assembled to the housing, so as to allow the connection of a clamp to a 12-volt battery cable (the 12-volt battery itself being difficult for the user to access as it is located under the vehicle body).
[0113] We proceed to an E22 step of assembling or mounting an electrical pack 10 in the housing 1. The E22 step includes the substeps El 1 to E19 previously described.
[0114] Following step E22, the electrical components 2, 3, 4, 5, 6, 7 were arranged so as to spatially distribute their connectors according to the nature of the connections for which they are intended. In particular, - The connectors of electrical components 2, 3, 4, 5, 6, 7 relating to a 48 Volt or 12 Volt power supply are preferably oriented towards the lateral face D of the housing, - the connections relating to the cooling of the electrical components, in particular the cooling of the first and second converters 4, 5 are oriented towards the side face A of the housing for connection to at least one hydraulic cooling duct 801. The side face A advantageously includes an opening for connection to an air duct 901.
[0115] Furthermore, following step E21, the side face A of the housing is oriented towards the front of the vehicle, this arrangement allowing maximum cooling of all the electrical components of the housing.
[0116] The side face D, providing access to all the electrical component connectors in the housing, is oriented towards the motor block. This arrangement simplifies the connection of the electrical components to the motor.
[0117] In the embodiment described with reference to [Fig. 16], the method of assembling a vehicle according to the invention comprises, following step E22, three steps E23, E24, E25 of connecting the electrical components 2, 3, 4, 5, 6, 7 of the electrical pack 10 to the other components 20, 30, 40, 50, 60, 70, 80, 90 of the motor vehicle 100. The pipes and cables implementing the connections are shown in Figures 17 to 19.
[0118] The third step E23 is a connection step of at least one hydraulic cooling line 801 to the first and second electrical converters 4, 5. On each of the converters, the connection requires a first fitting for the fluid inlet into the converter and a second fitting for the fluid outlet, the fluid circulating under pressure in the converter by means of the action of a pump located on the hydraulic cooling circuit comprising at least one hydraulic cooling line 801.
[0119] The fourth step E24 is a step of fixing the air duct 901 to the housing 1 of the electrical pack 10. This step includes connecting the air duct 901 to an opening arranged on the side face A of the housing 1.
[0120] The fifth step E25 is a step of connecting all the electrical components to the electrical wiring 600.
[0121] Step E25 includes a substep of connecting the 48 Volt battery 20 to terminal block 6.
[0122] Step E25 further includes a substep of connecting the terminal block 6 to the various equipment supplied with 48 Volts or 12 Volts via the electrical pack 10. In particular, step E25 therefore includes the connection of the terminal block 6 to the electric motor 50, the additional equipment 60 and the heating grid 70.
[0123] Step E25 also includes a sub-step of connecting the terminal block 6 to the other components of the electrical pack 10 for their power supply, in particular a connection of the terminal block 6 to the computer 3 and to the converters 4, 5.
[0124] Step E25 further includes a substep of connecting the safety element 7 to the 12 Volt battery 30, and to the various circuits dependent on the safety element 7. In other words, this substep includes a connection of the second 12 Volt supply circuit linking the converters 4, 5 and the engine control unit 2 to the 12 Volt battery 30 via the interconnection box 35 and the safety element 7.
[0125] Other embodiments of the method for assembling a vehicle 100 according to the invention are conceivable. For example, all or part of steps E23, E24, and E25 could be carried out before all or part of the steps for assembling the electrical pack. Furthermore, all or part of the substeps of step E25 for electrical connection could be distributed before, during, or after the assembly of the electrical pack.
[0126] For example, in order to facilitate certain connections in step E25, the sub-step of connecting the safety element 7 could preferably be carried out before mounting the safety element 7 on the housing 1.
[0127] In other words, the various connection steps and sub-steps have been described without presuming the order in which they are carried out.
[0128] In total, the advantages of the housing 1 according to the invention are numerous.
[0129] Firstly, the housing according to the invention provides a compact structure for an electrical pack including components necessary for the use of a 48V battery in the vehicle 100.
[0130] The electrical pack thus structured by the case is sufficiently compact to fit in the engine compartment, in a location initially allocated to a 12 Volt battery.
[0131] Therefore, thanks to the housing according to the invention, a 48-volt battery can be fitted to a vehicle initially designed to house only a 12-volt battery. The 48-volt battery installation is thus possible by installing the 12-volt and 48-volt batteries under the vehicle body, and by installing the electrical pack in the location initially intended for the 12-volt battery.
[0132] Furthermore, the installation of electrical components in the vehicle is facilitated by the ease of mounting these elements in the housing, thanks to the accessibility of the mounting structures provided by the housing. Electrical, hydraulic, and pneumatic connections are also facilitated by the spatial distribution of the connection connectors on different sides of the pack.
[0133] The housing was also designed with accessibility of the electrical pack components in mind, meeting both ergonomic and safety criteria. From an ergonomic standpoint, the 12-volt battery safety element was positioned to be easily accessible to the user. From a safety standpoint, the engine control unit was placed at the very back of the housing to complicate and delay access in the event of a malicious act against the vehicle.
[0134] In addition, the electrical pack groups together in a small space different components connected to each other, which makes it possible to reduce the length, and therefore the cost, of the electrical wiring between these components.
[0135] Finally, due to its dimensions being smaller than the bulk of a 12 Volt battery, such a box can be used in a wide range of vehicle models.
Claims
Claims
1. Housing (1) for electrical components of a motor vehicle (100) constituting a support for at least two or at least three electrical components, in particular at least two or at least three components from among: - a first 48V-12V electrical voltage converter (4), - a second 48V-12V electrical voltage converter (5), - an engine computer (2), - a heating grille computer (3), - a 12V battery safety element (7), and - an electrical terminal block (6), the housing comprising: - elements (E4, E5, A3, A4, A5, A6, C2, C3, C4, C5, 81, 82, 83, 84, 85, 86, AB, BC, CD, DA, 131, 132, 133, 134) for fixing the electrical components to the housing, and - elements (El, E2, E3) for fixing the housing with a fixing structure (110) of a motor vehicle, characterized in that it comprises arrangements making it possible to arrange the electrical components at least substantially parallel to each other,and in that its dimensions allow it to fit into a space provided for a 12V electric battery of type L3.,
2. Housing (1) for electrical components of a motor vehicle according to the preceding claim, characterized in that it comprises: - a first part (11) comprising five substantially planar faces (A, B, C, D, E) respectively constituting a base (E), of substantially rectangular shape, and four side walls (A, B, C, D) fixed perpendicular to the base (E), and - a cover (12) fitting onto the first part (11), the cover having a main face (F), in particular of substantially identical shape to the base (E), and, - a housing (13) fixed on the top of the main face (F) of the cover (12), the housing comprising a base (131, 132) and a cover (133).
3. Housing (1) for electrical components of a motor vehicle according to the preceding claim, characterized in that a first side wall (A, B, C, D) has an opening intended for a connection of the electrical components to an electrical connector and in that a second side wall (A, B, C, D) has an opening intended for connection of the electrical components to a cooling circuit.
4. Housing (1) for electrical components of a motor vehicle according to one of the preceding claims, characterized in that the arrangements are arranged so that the components are arranged: - horizontally, or - at an acute angle greater than or equal to 8° relative to the horizontal, or - vertically or substantially vertically.
5. Electrical pack (10) comprising a housing (1) for electrical components according to one of the preceding claims and at least two components or at least three of: - a first 48 Volt-12 Volt electrical voltage converter (2), - a second 48 Volt-12 Volt electrical voltage converter (3), - a motor computer (4), - a heating grid computer (5), - a 12 Volt battery safety element (7), and - an electrical terminal block (6).
6. Method for assembling an electrical pack (10) according to the preceding claim, characterized in that it comprises the following steps: - at least a first step of mounting a first electrical component in the housing, and - at least a second step of mounting a second electrical component in the housing, for example: - a first step (El 1) of placing the engine computer (2) on the base of the housing (E), - a second step (E12) of placing a first converter (4) above the engine computer (2), - a third step (El3) of placing a plate (8) above the first converter (4), - a fourth step (E14) of placing the second converter (5) above the plate (8), - a fifth step (E15) of fitting the cover (12) of the housing (1) onto the first part (11) of the housing (1), - a sixth step (E16) of placing the electrical terminal block (6) in the base (131, 132) of the housing (13) of the housing, - a seventh step (E17) of fitting the cover (133) of the housing (13) onto the base (131, 132) of the housing (13), - an eighth step (El8) of placing a heating grid calculator (3) onto the cover (133) of the housing (13), and - a ninth step (E19) of fixing a security element (7) onto the plate (8), the steps of placing a component comprising at least one assembly of the component to the housing (1).
7. Motor vehicle (100) comprising, in particular comprising in an engine compartment, an electrical pack (10) according to claim 5 or obtained by a method according to claim 6.
8. Method for assembling a motor vehicle (100), in particular a motor vehicle (100) according to the preceding claim, the vehicle comprising at least one hydraulic cooling duct (801), an air duct (901), electrical wiring (600) and a fixing structure (110), characterized in that the method comprises: - a first step (E21) of fixing a housing (1) to the fixing structure (110), - a second step (E22) of implementing the assembly method according to claim 6, - a third step (E23) of connecting the at least one hydraulic cooling duct (801) to the electrical pack (10), in particular to electrical converters (4, 5), - a fourth step (E24) of fixing the air duct (901) to the electrical pack (10), - a fifth step (E25) of connecting all of the electrical components to the electrical wiring (600).