Electric-Power Converter Signal Connector Relocation
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Solution Overview
Problem
In electric vehicles, the signal connector for the electric-power converter is prone to damage during collisions due to contact with the cowl top, which can prevent the discharge circuit from operating effectively, as it is typically placed on the top face and lacks adequate protection.
Innovation Solution
The signal connector is relocated to the side face of the electric-power converter, facing the vehicle width direction, ensuring it is protected from collision impacts by being positioned ahead of the cowl top's deformation, and the high-voltage connector is placed on the rear face below the cowl top to avoid contact with the cowl top during a collision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the signal connector is provided on the top face of the electric-power converter, then the connector placement is simple and accessible, but the signal connector is prone to damage during collisions due to contact with the cowl top
Solution Approach 1:
The signal connector is relocated from the top face (vertical dimension) to the side face (lateral dimension) of the electric-power converter housing. This dimensional change positions the connector in a spatial zone that is not affected by the cowl top deformation during front or oblique collisions, thereby protecting it from damage while maintaining accessibility for signal transmission.
2Reliability
If the signal connector is relocated to the front face to avoid cowl top contact, then collision protection is improved, but the front face easily receives impact at the time of front collision
Solution Approach 1:
Instead of moving the signal connector to the front face (longitudinal dimension), the connector is positioned on the side face (lateral dimension). This alternative dimensional placement avoids both the cowl top contact zone at the top and the impact zone at the front, finding a protected location in the lateral direction that is not exposed to collision forces.
3Area of stationary object
If the signal connector is placed on the rear face below the cowl top, then space utilization is improved, but the high-voltage connector placement is restricted
Solution Approach 1:
The rear face of the housing is segmented into different functional zones: the lower portion (below the cowl top) is designated for the high-voltage connector to ensure proper clearance and electrical isolation, while the side face is allocated for the signal connector. This segmentation allows both connectors to be properly positioned without spatial interference or placement conflicts.
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
This configuration significantly reduces the likelihood of signal connector damage during collisions, ensuring the discharge instruction signal can reach the discharge circuit and the capacitor is discharged properly, enhancing the safety and reliability of the electric-power converter system.
Implementation Method 1
a capacitor configured to restrain a high-frequency fluctuation in a voltage of electric power supplied from an electric power source
Implementation Method 2
a discharge circuit configured to discharge the capacitor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In an in-vehicle structure described in the present specification, an electric-power converter (10) is fixed onto a transaxle (37) and positioned in front of a cowl top (31). The electric-power converter (10) includes a capacitor configured to restrain a high-frequency fluctuation in a voltage of electric power supplied from a battery, and a discharge circuit configured to discharge the capacitor. A connector (14) to which a wiring harness (52) for communication of a discharge instruction signal to operate the discharge circuit at a time of a collision is connected is provided on a side face of the electric-power converter (10), the side face of the electric-power converter being facing in a vehicle width direction.