Onboard Charger Layout to Protect High-Voltage Circuits in Collisions
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Solution Overview
Problem
Existing vehicles with bi-directional chargers are susceptible to damage during collisions, which can expose high voltage circuits to the outside due to the proximity of adjacent units, posing a risk of electrical exposure and damage.
Innovation Solution
The vehicle design includes a first unit with an isolation transformer and electric circuits positioned to minimize exposure of high voltage circuits by locating them away from potential points of impact, using offset arrangements and recesses to maintain separation from adjacent units with high rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the first unit and second unit are disposed adjacent to each other to save space, then the vehicle can accommodate more components, but the casing of the first unit may be damaged during collision exposing high voltage circuits
Solution Approach 1:
The patent applies dimensional arrangement by positioning the first electric circuit at the front end of the casing in the vehicle front-rear direction, while the isolation transformer is positioned at the rear end. This spatial separation along the front-rear axis creates a protective buffer zone, ensuring that even if the casing is damaged during collision, the high voltage first electric circuit remains protected while the isolation transformer may be exposed.
2Device complexity
If the first electric circuit is positioned close to the isolation transformer to reduce component count, then the device complexity is reduced, but the high voltage circuit becomes more vulnerable to external damage
Solution Approach 1:
The patent segments the internal structure of the first unit by dividing it into distinct zones: the front end houses the high voltage first electric circuit, while the rear end houses the isolation transformer. This segmentation creates physical separation between components, with the front-end positioning of the high voltage circuit providing inherent protection through its location away from potential collision points.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents exposure of high voltage circuits to the outside even in the event of a collision, ensuring safety and reducing damage to the charging unit's casing.
Implementation Method 1
The isolation transformer includes a primary coil and a secondary coil. The first electric circuit is electrically connected to the primary coil of the isolation transformer. The second electric circuit is electrically connected to the secondary coil of the isolation transformer.
Data Source
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AI summary
A vehicle (10) includes: a motor (20); a battery (16) that is connected to the motor (20) through a system main relay (48); a first unit (24) that is connected to the battery through the system main relay (48); and a second unit (42) that is disposed adjacent to the first unit (24) on a first side in a vehicle front-rear direction. The first unit (24) includes: an isolation transformer (30) including a primary coil (30a) and a secondary coil (30b); a first electric circuit (32) that is connected to the primary coil (30a); and a second electric circuit (34) that is connected to the secondary coil (30b). The first electric circuit (32) is connected to the battery (16). The first electric circuit (32) is located closer to a second side in the vehicle front-rear direction than the isolation transformer (30).