Electric Power Controller Mounting Structure for Straddle-Type Electric Vehicle
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Solution Overview
Problem
Conventional electric vehicle designs require lengthy high-voltage lines connecting batteries to the motor controller, which are exposed and need covering, leading to complex wiring and increased electrical resistance.
Innovation Solution
The electric power controller is mounted to the electric storage device's accommodating box with an electrode terminal protruding for internal connection, minimizing high-voltage line length and eliminating the need for external covers, while allowing efficient cooling and protection from environmental elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the motor controller is placed separately from the battery box and connected via external high-voltage lines, then the motor controller can be cooled by ram air, but the high-voltage lines become exposed and require covers, increasing wiring complexity
Solution Approach 1:
The patent merges the motor controller and battery box into a single integrated assembly. The motor controller is mounted on the battery box such that its case forms part of the integrated structure, eliminating the need for separate external connections. This integration allows the motor controller to be cooled by ram air while avoiding exposed high-voltage lines, as the electrical connections are made through terminals that remain enclosed within the integrated assembly.
2Ease of manufacture
If high-voltage lines are exposed outside the battery box for connection to the motor controller, then wiring can be simplified, but the exposed lines require covers for safety, making wiring work messy
Solution Approach 1:
The patent applies the nesting principle by placing the motor controller inside or on the battery box structure, with the electrode terminals protruding through designated openings in the battery box. This nesting arrangement allows the high-voltage lines to remain enclosed within the battery box boundaries, eliminating the need for external covers while maintaining wiring simplicity. The terminals are nested within the battery box structure, providing both electrical connection and protective enclosure.
3Reliability
If many wiring members are used to connect high-voltage lines from batteries to the motor controller, then connections can be made, but electrical resistance loss increases
Solution Approach 1:
The patent extracts the high-voltage connection points directly into the battery box structure through designated openings. The electrode terminals are positioned to protrude through these openings, allowing direct electrical connection between the battery and motor controller without requiring multiple intermediate wiring members. This extraction of connection points eliminates unnecessary wiring components, reducing electrical resistance loss while maintaining reliable connections.
Data Source
AI summary
A straddle-type electric vehicle (e.g., electric motorcycle 1) comprising a driving motor and an electric power control unit for controlling electric power supplied from batteries to the driving motor, a case of the electric power control unit is mounted from a location outward of the battery box, and electrode terminals protruding outward from the case are inserted into insertion holes of the battery box. The electrode terminals protruding into inside of the battery box are connected to electrodes of the batteries via electric conductors such as bus bars. In this structure, electric connecting work between the batteries and the electric power control unit can be easily carried out, high-voltage lines can be minimized in length, and the high-voltage lines are not exposed to the outside.