EV Battery Device Layout for Shorter Wire Harnesses
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Solution Overview
Problem
Existing electric vehicles with batteries located below the floor lack efficient arrangements for battery-related devices, leading to potential weight and power loss issues due to lengthy wire harnesses and suboptimal positioning of components.
Innovation Solution
The electric vehicle design includes a battery positioned between the front and rear wheels, with integrated electromechanical units located forward and rearward of the battery, and battery-related devices disposed below the second-row seat and above the integrated electromechanical units, optimizing the layout to reduce wire harness lengths and improve safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If battery-related devices are arranged in a conventional layout, then device installation is simplified, but wire harness lengths increase causing weight increase and power loss
Solution Approach 1:
The patent transitions from a two-dimensional floor plan arrangement to a three-dimensional vertical arrangement by placing battery-related devices in the space between the floor and the battery pack. This vertical utilization of space enables shorter wire harness connections while maintaining installation feasibility, thereby reducing power loss without significantly increasing layout complexity.
Solution Approach 2:
The patent nests battery-related devices within the existing vehicle structure by positioning them in the vertical space between the floor and the battery pack. This nesting approach allows the devices to be integrated into the existing structural framework, minimizing additional complexity while achieving shorter wire harness lengths and reduced power loss.
2Weight of moving object
If battery-related devices are positioned closer to the battery, then wire harness lengths are reduced decreasing weight and power loss, but device arrangement becomes more constrained
Solution Approach 1:
The patent resolves the arrangement constraint by utilizing the vertical dimension between the floor and battery pack, transforming a potentially constrained two-dimensional placement problem into a more flexible three-dimensional space utilization solution. This enables closer positioning of devices to the battery while maintaining ease of installation and maintenance access.
Solution Approach 2:
The patent applies local quality by specifically targeting the vertical space in the region between the floor and battery pack for device placement. This localized utilization of space optimizes the specific area for weight reduction purposes while maintaining overall vehicle assembly feasibility and operational accessibility.
3Volume of moving object
If battery-related devices are arranged below the floor, then passenger space is maximized, but wire harness lengths increase causing increased power loss
Solution Approach 1:
The patent shifts the arrangement from a horizontal two-dimensional layout below the floor to a vertical three-dimensional arrangement between the floor and battery pack. This dimensional transition maintains passenger space optimization while dramatically reducing wire harness lengths and associated power losses.
Solution Approach 2:
The patent introduces the vertical space between the floor and battery pack as an intermediary location for battery-related devices. This intermediary positioning serves as an optimal compromise that preserves passenger space while enabling shorter electrical connections and reduced power loss compared to arrangements below the floor.
4Ease of operation
If integrated electromechanical units are positioned far from the battery, then motor control is simplified, but wire harness lengths increase causing weight increase
Solution Approach 1:
The patent utilizes vertical positioning between the floor and battery pack to relocate integrated electromechanical units closer to the battery. This three-dimensional arrangement reduces wire harness lengths and associated weight while maintaining motor control functionality through optimized electrical connections.
Solution Approach 2:
The patent applies local quality by concentrating battery-related devices including electromechanical units in the specific vertical region between the floor and battery pack. This localized arrangement minimizes wire harness lengths and weight in critical areas while preserving motor control capabilities through optimized electrical connectivity.
Data Source
AI summary
A first-row seat and a second-row seat are arranged on a floor of a vehicle. The second-row seat is located rearward of the first-row seat. A battery is arranged below the floor. A second integrated electromechanical unit is arranged rearward of the battery. The electric vehicle includes a vehicle on-board charger, a battery ECU, and a junction box as battery-related devices. The battery ECU and the junction box are located below the second-row seat and above the battery. The vehicle on-board charger is located above the second integrated electromechanical unit.