Conducting Chassis Frame Beam for High-Voltage Cable Routing
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Solution Overview
Problem
Existing chassis frame beams in commercial vehicles and industrial machines are inefficient in routing high voltage DC cables, occupying valuable space and limiting the design flexibility and energy storage capacity.
Innovation Solution
Integrate a conductive material with an insulation layer into the chassis frame beam to form a conductor part, allowing it to carry current and connect electrical sources and loads, thereby eliminating the need for separate cables and optimizing space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional separate cables are used for high voltage DC routing, then electrical connections can be established, but valuable chassis space is occupied and design flexibility is limited
Solution Approach 1:
The patent merges the electrical cable function with the chassis frame beam structure by integrating a conductive material and insulation layer directly into the beam. This combination eliminates the need for separate cables, freeing up chassis space while maintaining electrical connectivity and improving design flexibility.
Solution Approach 2:
The chassis frame beam is designed to serve multiple functions: it provides structural support and simultaneously acts as an electrical conductor for high voltage DC routing. This multi-functionality reduces the overall space required in the chassis while enhancing adaptability for different electrical configurations.
2Strength
If traditional beams are used for chassis frame, then structural support is provided, but space for energy storage is reduced
Solution Approach 1:
The electrical conductor is integrated within the existing beam structure, combining the structural support function with the electrical conduction function. This eliminates the need for additional space-consuming cables while maintaining full structural integrity and maximizing energy storage space.
3Volume of moving object
If conductor part is integrated into beam, then cable routing is improved and space is freed, but insulation and electrical safety become more complex
Solution Approach 1:
The insulation layer is applied locally only where needed within the beam structure, surrounding the conductive material in specific zones. This localized approach provides necessary electrical safety while minimizing added complexity and maximizing the remaining available space for other components.
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
Enhances energy storage capacity and design flexibility by integrating electrical pathways into the chassis frame, enabling larger battery ranges in electric vehicles and additional equipment in industrial machines.
Implementation Method 1
an insulation layer surrounding the conductive material to prevent current from flowing from the conductor part to the remainder of the beam
Implementation Method 2
the conductor part of the beam carries current in the electric circuit
Data Source
AI summary
A chassis frame beam is described. At least a part of the beam is conducting and comprises a conductor part having a conductive material and an insulation layer surrounding the conductive material to prevent current from flowing from the conductor part to the remainder of the beam. An opening in the conductor part is arranged to connect the conductor part to an electrical source and/or load to form an electric circuit. The conductor part of the beam carries current in the electric circuit.