Electric Unit Connector Cowl Rigidity Weight
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Solution Overview
Problem
Increasing the rigidity of the cowl in electric powered vehicles to prevent deformation while minimizing weight, as large reinforcements lead to increased vehicle weight and potential noise or vibration issues.
Innovation Solution
A configuration that connects the electric unit to the cowl via a lightweight connector, with the electric unit being supported by a mount frame and the cowl reinforced at its intermediate portion, using high-voltage components like power converters housed in electrically insulating materials, and connecting the cowl ends to suspension towers or apron upper members for enhanced stability and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large reinforcement is joined to the cowl to increase rigidity, then deformation of the cowl is suppressed, but vehicle weight increases
Solution Approach 1:
The patent combines the reinforcement function with the electric unit mounting structure. The electric unit itself serves as a reinforcement element by being directly connected to the cowl, eliminating the need for separate large reinforcement pieces. This merging approach provides both structural support and functional integration, suppressing cowl deformation without adding excessive weight.
Solution Approach 2:
The electric unit serves multiple functions: it provides electrical power conversion and simultaneously acts as a structural reinforcement for the cowl. By making the electric unit directly support the cowl, the structure achieves multi-functionality, where the same component performs both electrical and structural roles, avoiding additional weight from dedicated reinforcement elements.
2Weight of moving object
If a simple connector is used to connect the electric unit to the cowl, then vehicle weight is suppressed, but deformation suppression effectiveness may be reduced
Solution Approach 1:
The connector is integrated with the electric unit housing, merging the connection function into the existing structural component. This integration allows the connector to serve both as an electrical mounting point and as a structural reinforcement element, achieving effective deformation suppression without requiring a separate, heavy reinforcement component.
Solution Approach 2:
The electric unit and connector are designed and positioned in advance to provide preliminary structural support to the cowl. By pre-configuring the electric unit as a support element during the design phase, the structure is prepared to resist deformation before actual use, eliminating the need for additional reinforcement measures.
3Strength
If the cowl is connected to the electric unit, then cowl rigidity is improved, but noise and vibration may be generated in engine vehicles
Solution Approach 1:
The patent replaces the traditional engine-mounted reinforcement system with an electric unit-based system. Since electric units do not generate vibration or noise like combustion engines, connecting the cowl to the electric unit avoids the harmful noise and vibration issues while still achieving the desired rigidity improvement.
Data Source
AI summary
An electric powered vehicle includes a motor for driving one or more wheels. The electric powered vehicle may include a body including a dash panel, a cowl disposed along an upper end of the dash panel and at least partly located forward of the dash panel, an electric unit located forward of the dash panel and supported by the body, and a connector connecting the electric unit and an intermediate portion of the cowl to each other.