BEV Power Cable Support Bracket for Swing Fatigue Reduction
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Solution Overview
Problem
In battery electric vehicles, the swinging of the power cable connecting the motor and the inverter relative to the chassis leads to fatigue degradation due to excessive movement, which is not effectively addressed by existing technologies.
Innovation Solution
The power cable is supported by a support bracket positioned closer to the center of the circular arc than half the radius, dividing its swinging into two components, and is fixed to the chassis at one end, with orthogonal bending to reduce vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the motor is supported by the suspension together with the axle, then the motor can move with the suspension motion, but the power cable swings greatly causing fatigue degradation
Solution Approach 1:
The power cable path is segmented into two sections by introducing a support bracket: one section from the inverter to the support bracket, and another from the support bracket to the motor. This segmentation allows each section to have different swing characteristics, with the support bracket positioned to minimize the swing amplitude of the cable portions, thereby reducing fatigue degradation while maintaining motor suspension motion capability.
2Reliability
If the power cable is fixed rigidly to reduce swinging, then cable fatigue is reduced, but the motor suspension motion is constrained
Solution Approach 1:
A support bracket is introduced as an intermediary component to support the power cable at an intermediate position between the inverter and the motor. This intermediary support structure reduces the swing amplitude of the power cable by providing a stable attachment point closer to the center of the circular arc trajectory, thereby protecting the cable from fatigue degradation while allowing the motor to maintain its suspension motion capability.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A battery electric vehicle (2) including an axle (4), a motor (5), a suspension (10), an inverter (6), a power cable (7), and a support bracket (21) is provided. The axle (4) extends in a vehicle-width direction. The motor (5) is coupled to the axle (4), and drives the axle (4). The suspension (10) supports the axle (4) and the motor (5), and causes the axle (4) and the motor (5) to swing along a circular arc when viewed in the vehicle-width direction. The inverter (6) is fixed to a chassis (3a), and supplies electric power to the motor (5). The power cable (7) connects the inverter (6) and the motor (5). The support bracket (21) supports the power cable (7), and swings together with the motor (5). The power cable (7) is supported by the support bracket (21), at a position that is closer to the center (Pv) of the circular arc than a position of half of the radius of the circular arc is when viewed in the vehicle-width direction.