Electric Vehicle Battery Case Wire Routing
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Solution Overview
Problem
The existing electric vehicles face challenges in maximizing space efficiency and protecting electric wires while maintaining a clean external appearance, as large currents require protective measures that can compromise these aspects.
Innovation Solution
The electric vehicle design incorporates an electric wire that runs through the internal space of a battery case, reducing wire length and allowing the battery case to protect the wire, with a configuration that includes a motor case and bus bars for three-phase AC current, and an electric cable for flexibility, all while utilizing the battery case's internal space for cooling passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric wire is protected by an additional protecting structure, then the electric wire is protected from outside, but the space efficiency of the electric vehicle is reduced
Solution Approach 1:
The battery case is designed to serve dual functions: accommodating the battery and protecting the electric wire. By routing the electric wire through the internal space of the battery case, the battery case becomes a multi-functional component that provides both battery storage and wire protection without requiring additional protecting structures.
Solution Approach 2:
The electric wire is nested within the internal space of the battery case, allowing the wire to be protected while occupying space that would otherwise be unused. This nesting approach enables the wire to be housed within the existing battery case structure rather than requiring separate protection.
2Reliability
If the electric wire is protected by an additional protecting structure, then the electric wire is protected from outside, but the external appearance of the electric vehicle is degraded
Solution Approach 1:
The battery case serves as both the battery housing and the protective covering for the electric wire. This eliminates the need for additional protecting structures that would be visible externally and potentially degrade the vehicle's appearance.
Solution Approach 2:
The protection function is extracted from a separate protecting structure and integrated into the battery case itself. By taking the protection function and embedding it within the existing battery case design, the solution avoids adding external protecting elements that would affect appearance.
3Length of moving object
If the battery case is placed between the electric motor and the inverter, then the distance from battery to inverter and battery to electric motor is reduced, but the wiring operation becomes more complex
Solution Approach 1:
The electric wire is routed vertically through the internal space of the battery case, utilizing the vertical dimension to connect components. This vertical routing through the battery case's internal space simplifies the wiring path compared to external routing, making the wiring operation more manageable despite the compact arrangement.
Data Source
AI summary
An electric vehicle includes an electric motor which generates a driving power for driving a wheel, a battery storing DC power to be supplied to the electric motor, a battery case accommodating the battery in a battery space in an interior of the battery case, an inverter which converts the DC power supplied from the battery and supplies electric power to the electric motor, and an electric wire connecting the inverter to the electric motor. The electric wire runs through an internal space of the battery case, and may penetrate an upper surface of the battery case, protrude upward, and connect to an inverter placed on an upper portion of the battery case. The electric wire may run through a cooling passage in the internal space. The electric wire may be interposed between the electric motor and the inverter. The electric wire may run vertically through the internal space.