Electric Unit High-Voltage Component Protection via Low-Voltage Buffer
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Solution Overview
Problem
Existing electric units in electric and hybrid vehicles face challenges in preventing high-voltage components from being externally exposed during impacts without increasing the unit's size, as they require additional components for contact interruption which enlarges the unit.
Innovation Solution
The electric unit is designed with a high-voltage component positioned towards the front and a low-voltage component towards the rear within an accommodation case, where the low-voltage component acts as a buffer to protect the high-voltage component by arranging the control board larger in height or width, preventing exposure even if the case is fractured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a component dedicated to interruption of contact with high-voltage component is installed, then the high-voltage component is protected from external exposure, but the size of the electric unit increases
Solution Approach 1:
The patent merges the protective function with the existing low-voltage component (control device). The low-voltage component is positioned to serve dual purposes: its original control function and acting as a protective barrier against high-voltage component exposure during collisions. This eliminates the need for a separate dedicated protective component.
Solution Approach 2:
The low-voltage component is designed to perform multiple functions: it serves as both the control device for the electric power conversion device and as a protective barrier that interrupts contact with high-voltage components during external impacts. This multi-functionality resolves the contradiction by eliminating the need for additional dedicated protective components.
2Reliability
If the electric unit size is increased to protect high-voltage component, then the protection effectiveness is improved, but the installation space in vehicle front increases
Solution Approach 1:
The protective function is merged into the existing low-voltage component structure. By positioning the low-voltage component between the high-voltage component and the external environment, the patent achieves protection without requiring additional space for a separate protective barrier.
Solution Approach 2:
The patent utilizes the spatial arrangement within the accommodation case, positioning the low-voltage component in a specific dimension (front-rear direction) to create a protective barrier. This dimensional arrangement allows protection to be achieved through reconfiguration of existing components rather than adding volume.
Data Source
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AI summary
An electric unit is attached to a power unit including a motor-generator, the power unit being disposed in a power unit mounting chamber that is formed at a front of a vehicle and separated from a vehicle cabin by a partition wall. The electric unit includes: a high-voltage component including an electric power conversion device of a relatively high voltage, the electric power conversion device converting an electric power between a DC electric power and an AC electric power for the motor-generator; and a low-voltage component including a control device of a relatively low voltage, the control deice controlling the electric power conversion device. The high-voltage component and the low-voltage component are accommodated in an accommodation case. Inside the accommodation case, the high-voltage component is arranged toward the front of the vehicle, and the low-voltage component is arranged toward a rear of the vehicle.