Vehicle

Abstract

To provide a technique to protect, at the time of front collision, a cable supplying power to a power control unit.SOLUTION: A vehicle comprises a power control unit that is arranged on a top face of a power unit inside a front compartment, and supplies power to a motor. The vehicle comprises a rear bracket that is located behind the power control unit, and fixes the power control unit to the power unit. The vehicle comprises a cable that supplies high-voltage power to the power control unit. The rear bracket comprises a plate-like base that is located along the top face of the power unit, and a support part that extends upward from the base and is located along a rear side face of the power control unit. An outer peripheral edge of the base includes a first specific edge that extends along a vehicle width direction and faces the cable in a vehicle fore-and-aft direction. The first specific edge is subjected to curling treatment or chamfering treatment.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a vehicle in which a traveling motor and a power control unit for driving the motor are mounted in a front compartment of the vehicle.

Background Art

[0002] Patent Document 1 discloses a structure in which a power unit and a power control unit are mounted in a front compartment of a vehicle. The power unit houses a traveling motor. The power control unit includes an inverter, a boost converter, etc., and supplies power to the motor. In the technology disclosed in Patent Document 1, the power control unit is fixed above the power unit. And, the front and rear portions of the power control unit in the vehicle longitudinal direction are supported by a front bracket and a rear bracket. Also, a cable for supplying high-voltage power is connected to the power control unit.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] There are cases where the edge on the vehicle rear side of the rear bracket faces the high-voltage cable in the vehicle longitudinal direction. Then, when a frontal collision occurs, the rear bracket moves toward the vehicle rear side, and there is a risk that the cable will be damaged when the edge of the rear bracket comes into contact with the cable.

Means for Solving the Problems

[0005] The vehicle targeted by the technology disclosed in this specification includes a vehicle body having a front compartment. The vehicle includes a power unit that is disposed within the front compartment and houses at least a motor for driving. The vehicle includes a power control unit that is disposed on the upper surface of the power unit and supplies power to the motor. The vehicle includes a rear bracket that is positioned rearward in the vehicle's longitudinal direction with respect to the power control unit and fixes the power control unit to the power unit. The vehicle includes a cable that is connected to the power control unit and supplies high-voltage power to the power control unit. The rear bracket includes a plate-shaped base portion that is positioned along the upper surface of the power unit, and a support portion that extends upward from the base portion and is positioned along the rear side surface of the power control unit. The outer peripheral edge of the base portion extends along the vehicle width direction and includes a first specific edge that faces the cable in the vehicle's longitudinal direction. The first specific edge is subjected to curling or chamfering.

[0006] According to the above structure, when the first specific edge comes into contact with the cable, the contact area can be increased as compared with the case where curling or chamfering is not performed. When the first specific edge contacts the cable, the load applied to the cable can be dispersed, so that damage to the cable can be suppressed.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Best Mode for Carrying Out the Invention

[0008] In a vehicle as an example disclosed in this specification, the first specific edge may be curled with a radius of curvature equal to or greater than the thickness of the base. According to this configuration, when the first specific edge contacts the cable, the contact area can be appropriately increased. It becomes possible to disperse the load applied to the cable.

[0009] In a vehicle as an example disclosed in this specification, the first specific edge may be curled so that its tip surface is not located at the most rearward position in the vehicle longitudinal direction. According to this configuration, it is possible to prevent the tip surface of the first specific edge from contacting the cable. Since it is possible to prevent a situation where a concentrated load is applied to the cable by the tip surface, it becomes possible to suppress damage to the cable.

[0010] In a vehicle as an example disclosed in this specification, the outer peripheral edge of the base may further include a second specific edge that extends along the vehicle width direction and faces the cable in the vehicle longitudinal direction. The second specific edge may be located in front of the first specific edge in the vehicle longitudinal direction. Curling may be performed on the second specific edge. The possibility of contacting the cable during a frontal collision is lower for the second specific edge than for the first specific edge. According to this configuration, since curling is not performed on the second specific edge, the processing difficulty of the rear bracket can be reduced. It becomes possible to reduce the manufacturing cost of the rear bracket.

[0011] In a vehicle as an example disclosed in this specification, the first specific edge may be chamfered with a chamfer amount equal to or less than half of the thickness of the base. According to this configuration, when the first specific edge contacts the cable, the contact area can be appropriately increased. It becomes possible to suppress damage to the cable.

Examples

[0012] (Schematic Structure of Power Control Unit 20 and Motor Housing 30) Referring to FIG. 1, the electric vehicle 1 of the embodiment will be described. In FIG. 1, the coordinate system indicates that FR represents the front of the vehicle, UP represents the upper part of the vehicle, and LH represents the left in the vehicle width direction. The meanings of the symbols of the coordinate system are the same in the subsequent figures. Note that the electric vehicle 1 in this specification includes not only electric vehicles but also hybrid vehicles and fuel cell vehicles.

[0013] The electric vehicle 1 is provided with a front compartment 90 at the front part of the vehicle. The front compartment 90 is separated from the cabin by a dash panel 91. The power control unit 20 and the motor housing 30 are stored in the front compartment 90. Note that various other devices are also arranged in the front compartment 90, but their descriptions are omitted. Also, for the sake of simplicity, hereinafter, the "power control unit 20" may be abbreviated as "PCU20". PCU is the abbreviation of Power Control Unit.

[0014] The motor housing 30 is, for example, a case made of aluminum die-casting or machining. At least the driving motor 3 is housed in the motor housing 30. The PCU20 is arranged on the upper surface of the motor housing 30. The PCU20 is a device for driving the motor 3. More specifically, the PCU20 boosts the power of a high-voltage battery (not shown), then converts it into alternating current and supplies it to the motor 3. The PCU20 may also convert the alternating current power generated by the motor 3 into direct current power and further step it down. The high-voltage battery is charged with the stepped-down power.

[0015] Fig. 2 shows a side view of the PCU 20 and the motor housing 30. In Fig. 2, for the sake of understanding, a part of the dash panel 91 is shown by a phantom line. As described above, the motor 3 is housed in the motor housing 30. The front bracket 10 supports the front surface 20a of the PCU 20. The rear bracket 40 supports the rear side surface 20r of the PCU 20. The structure of the rear bracket 40 will be described later. A gap SP is secured between the lower surface 20b of the PCU 20 and the motor housing 30. The upper surface 30u of the motor housing 30 is inclined downward at the front. Therefore, the PCU 20 supported above the upper surface 30u is also arranged to be inclined downward at the front.

[0016] The cable 24 is connected to the terminal box 23 provided on the rear side surface 20r of the PCU 20. The cable 24 is connected to a high-voltage battery (not shown) through the gap between the rear vehicle side of the rear bracket 40 and the dash panel 91. The cable 24 is a cable that supplies high-voltage power to the PCU 20. Here, "high voltage" means an operating voltage exceeding 60V DC and 1500V or less, or exceeding 30V (rms) AC and 1000V (rms) or less. In this embodiment, the cable 24 is a high-voltage cable of 650V DC. Since high-voltage power flows through the cable 24, it is desirable to avoid damage to the cable 24 when the electric vehicle 1 collides. This is to avoid exposure of the high-voltage conductor inside the cable 24.

[0017] (Structure of the rear bracket 40) The structure of the rear bracket 40 will be described with reference to Figs. 3 and 4. Fig. 3 is a top view of the rear bracket 40. Figs. 4(A) and (B) are cross-sectional views taken along the lines A-A and B-B of Fig. 3, respectively. That is, Fig. 4(A) is a cross-sectional view of a first specific edge E1 described later, and Fig. 4(B) is a cross-sectional view of a second specific edge E2. In Figs. 3 and 4, for the sake of understanding, a part of the cable 24, the power control unit 20, and the motor housing 30 is shown by a phantom line.

[0018] The rear bracket 40 is made by pressing a metal plate (steel plate). The rear bracket 40 includes a base portion 40b and a support portion 40s. The base portion 40b is a plate-shaped part located along the upper surface 30u of the motor housing 30. The base portion 40b is fixed to the upper surface 30u by bolts 51. The support portion 40s extends upward from the base portion 40b. The support portion 40s includes a part located along the rear side surface 20r of the PCU 20. The upper part of the support portion 40s is fixed to the rear side surface 20r by bolts 52.

[0019] As shown in FIG. 3, the outer peripheral edge of the base portion 40b includes a first specific edge E1 and a second specific edge E2. The first specific edge E1 and the second specific edge E2 extend along the vehicle width direction and are edges that face the cable 24 in the vehicle front-rear direction. Also, the second specific edge E2 is located on the vehicle front side of the first specific edge E1.

[0020] The width of the base portion 40b in the vehicle front-rear direction is smaller in the region where the second specific edge E2 is formed than in the region where the first specific edge E1 is formed. In other words, the formation of the second specific edge E2 forms a notch in the base portion 40b. The function of this notch will be explained. First, by reducing the material, the rear bracket 40 can be lightened. Second, when a collision load of a predetermined magnitude or more is received, the rear bracket 40 can be deformed by the notch. Thereby, a part of the collision load can be received by the deformation of the rear bracket 40. Since load concentration on the connection portion between the rear bracket 40 and the motor housing 30 can be prevented, damage to the connection portion can be suppressed.

[0021] Using FIG. 4(A), the cross-sectional shape of the first specific edge E1 will be explained. A standing wall portion 40w and a curled portion 40c are formed on the first specific edge E1. The standing wall portion 40w and the curled portion 40c are formed in the vehicle width direction over the entire length of the first specific edge E1. The strength of the base portion 40b made of a metal plate can be increased by the standing wall portion 40w.

[0022] The curled portion 40c is a portion formed by curling. The curled portion 40c has a shape that roundly wraps the front end surface 40t of the first specific edge E1 toward the front side of the vehicle. The curled portion 40c also has a rear end portion 40r that is located most rearward in the vehicle. And the front end surface 40t is located on the front side of the vehicle relative to the rear end portion 40r. That is, the curling process is performed so that the front end surface 40t is not located most rearward in the vehicle.

[0023] Also, the first specific edge E1 is subjected to curling with a radius of curvature R1. And the radius of curvature R1 is equal to or greater than the thickness T1 of the base portion 40b.

[0024] Using FIG. 4(B), the cross-sectional shape of the second specific edge E2 will be described. The second specific edge E2 is not formed with a standing wall portion 40w and a curled portion 40c. That is, the second specific edge E2 is not subjected to curling. The effect will be described. The second specific edge E2 is located more forward in the vehicle than the first specific edge E1. Therefore, the possibility of contacting the cable 24 during a frontal collision is lower for the second specific edge E2 than for the first specific edge E1. Accordingly, there are few problems even if no curled portion is formed on the second specific edge E2. Since the curling process for the second specific edge E2 can be omitted, the processing difficulty of the rear bracket 40 can be reduced. It becomes possible to reduce the manufacturing cost of the rear bracket 40.

[0025] (Effect) Explain the effect of the curling process. When the electric vehicle 1 undergoes a frontal collision (or an oblique frontal collision), the rear bracket 40 may move rearward of the vehicle together with the PCU 20 (see arrow Y1 in FIGS. 3 and 4). A situation may occur where the cable 24 is pinched between the first specific edge E1 of the rear bracket 40 and various members (e.g., the dash panel 91) existing on the rear side of the vehicle of the cable 24. At this time, when the tip surface 40t of the rear bracket 40 contacts the cable 24, a concentrated load is applied to the cable 24 by the tip surface 40t, and the cable 24 may be damaged or disconnected. Since a high voltage is applied to the cable 24, this is not preferable from the viewpoint of collision safety. Therefore, in the technique of Example 1, curling is performed on the first specific edge E1 that may contact the cable 24 during a collision. As a result, the tip surface 40t can be hidden inside the rear bracket 40 so that the tip surface 40t is not located on the most rear side of the vehicle. Therefore, even when the first specific edge E1 contacts the cable 24, it is possible to prevent the tip surface 40t from contacting the cable 24. Since it is possible to prevent a situation where a concentrated load is applied to the cable 24 by the tip surface 40t, it is possible to suppress damage to the cable 24.

[0026] Further, the radius of curvature R1 of the curled portion 40c is set to be equal to or greater than the thickness T1 of the base portion 40b. Thereby, the contact area when the curled portion 40c contacts the cable 24 can be appropriately increased. By dispersing the load applied to the cable 24, it is possible to suppress damage to the cable 24.

[0027] The position on the most rear side of the base portion 40b is a position where an operator is highly likely to come into contact. Also, this position is a position where it is necessary to improve the painting quality in order to prevent the occurrence of rust and the like. In the technique of this embodiment, the curled portion 40c can be positioned at this most rear side position. Since the curled portion 40c is not as sharp as the tip surface 40t, it is possible to prevent injury when an operator comes into contact. Also, since the curled portion 40c can form a thicker paint film than the tip surface 40t, the painting quality can be improved.

[0028] (Modification of Example 1) Fig. 5 shows a cross-sectional view of the rear bracket 140 of the modification. Fig. 5 is a cross-sectional view at the same position as Fig. 4(A). The curled portion 40c (Fig. 4(A)) of Example 1 curls the tip surface 40t roundly toward the front side of the vehicle. On the other hand, the curled portion 140c (Fig. 5) of the modification has a shape that curls the tip surface 40t roundly toward the rear side of the vehicle. Note that parts common to Example 1 are denoted by common reference numerals and the description thereof is omitted.

[0029] The curled portion 140c includes a rear end portion 140r that is located farthest to the rear of the vehicle. And the tip surface 40t is located on the front side of the vehicle relative to the rear end portion 140r. Thereby, even when the first specific edge E1 contacts the cable 24, it is possible to prevent the tip surface 40t from contacting the cable 24. Also, the radius of curvature R2 of the curled portion 140c is set to be equal to or greater than the thickness T1 of the base portion 40b. Thereby, by dispersing the load applied to the cable 24, it becomes possible to suppress damage to the cable 24.

Example

[0030] Fig. 6(A) shows a cross-sectional view of the rear bracket 240 of Example 2. Fig. 6(A) is a cross-sectional view at the same position as Fig. 4(A) and is an enlarged view of the vicinity of the tip surface 40t. In Example 1, the curled portion 40c (Fig. 4(A)) was formed on the first specific edge E1 by curling. In Example 2, chamfering is performed on the first specific edge E1 instead of curling. Note that parts common to Example 1 are denoted by common reference numerals and the description thereof is omitted.

[0031] The tip surface 40t of the first specific edge E1 is located on the rearmost side of the vehicle. Chamfering is performed on the corner CP on the vehicle rear side of the tip surface 40t. In FIG. 6(A), the portion removed by the chamfering is indicated by a dashed line. Specifically, a position separated by a chamfer amount CA from the corner CP is cut at 45°. Thereby, the C surface 240s is formed. Further, the chamfer amount CA of the chamfering is set to be equal to or less than half of the thickness T1 of the base 40b.

[0032] (Effect) The C surface 240s can be formed on the tip surface 40t by chamfering. Thereby, the contact area when the tip surface 40t contacts the cable 24 can be appropriately increased. By dispersing the load applied to the cable 24, it becomes possible to suppress damage to the cable 24.

[0033] Also, by setting the chamfer amount CA to be equal to or less than half of the thickness T1, the width W1 in the thickness direction of the remaining tip surface 40t does not become unnecessarily narrow. This also makes it possible to appropriately increase the contact area when the tip surface 40t contacts the cable 24.

[0034] (Modification of Example 2) FIG. 6(B) shows a cross-sectional view of the modified rear bracket 340. FIG. 6(B) is a cross-sectional view at the same position as FIG. 6(A). Note that parts common to Example 2 are denoted by the same reference numerals and the description thereof is omitted.

[0035] In the modification of FIG. 6(B), rounding with a radius of curvature R3 is performed on the corner CP. Thereby, the rounded surface 340s is formed. Further, the radius of curvature R3 is set to be equal to or less than half of the thickness T1 of the base 40b. The formation of the rounded surface 340s makes it possible to appropriately increase the contact area when the tip surface 40t contacts the cable 24.

[0036] As described above, specific examples of the present invention have been described in detail, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes to the specific examples illustrated above. The technical elements described in this specification or the drawings exhibit technical utility alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. Further, the technology illustrated in this specification or the drawings can achieve a plurality of purposes simultaneously, and achieving one of those purposes itself has technical utility.

[0037] (Modification example) The first specific edge E1 may not be provided with the vertical wall portion 40w. For example, a curl portion 40c, a C surface 240s, a round surface 340s, etc. may be formed at the end of the base portion 40b on the rear side of the vehicle.

[0038] The edge where chamfering or rounding is performed is not limited to the first specific edge E1. Considering collisions and variations in processing, it is possible to flexibly determine the setting area of the edge where chamfering is performed.

[0039] The connection destination of the cable 24 is not limited to the high-voltage battery and may be various parts.

[0040] Both curling and chamfering may be performed on the first specific edge E1.

[0041] The motor housing 30 is an example of a power unit.

Explanation of reference numerals

[0042] 1: Electric vehicle 10: Front bracket 20: Power control unit 20r: Rear surface 24: Cable 30: Motor housing 40: Rear bracket 40b: Base portion 40s: Support portion 40t: Tip surface 40c: Curl portion E1: First specific edge E2: Second specific edge 90: Front compartment 91: Dash panel

Claims

【Claim 1】 A vehicle body having a front compartment, a power unit disposed within the front compartment and housing at least a motor for running, a power control unit disposed on the upper surface of the power unit and supplying electric power to the motor, a rear bracket positioned rearward in the vehicle's longitudinal direction with respect to the power control unit and fixing the power control unit to the power unit, a cable connected to the power control unit and supplying high-voltage electric power to the power control unit, comprising: The rear bracket: a plate-shaped base portion positioned along the upper surface of the power unit, a support portion extending upward from the base portion and positioned along the rear side surface of the power control unit, comprising: The outer peripheral edge of the base portion extends along the vehicle width direction and includes a first specific edge facing the cable in the vehicle's longitudinal direction, The first specific edge has a radius of curvature equal to or greater than the thickness of the base portion and is subjected to curling, The curling is performed such that the tip surface of the first specific edge is not positioned most rearward in the vehicle's longitudinal direction, The outer peripheral edge of the base portion further includes a second specific edge extending along the vehicle width direction and facing the cable in the vehicle's longitudinal direction, The second specific edge is positioned forward of the first specific edge in the vehicle's longitudinal direction, The second specific edge is not subjected to the curling, Vehicle.

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