EV Front Charging Unit Bracket Structure for Impact Protection
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Solution Overview
Problem
Existing electric vehicle front structures face challenges in ensuring rigidity and space for charging units, particularly in vehicles with narrow front compartments, where a movable arm for the charging port is difficult to implement, and the charging port's low position increases the risk of impact and complicates charging operations.
Innovation Solution
A front structure featuring vehicle body frames, bumper crossmembers, and a connector receiver with a charging unit, bracket, and dash panel arrangement that ensures rigidity and stability for the charging unit, allowing for easy charging operations and impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a movable arm is used to support the charging port, then the charging port can withstand operational loads, but space is required for the connector receiver to move in the vehicle front-rear direction which may not be available in narrow front compartments
Solution Approach 1:
The charging port is made movable in the vehicle front-rear direction through a movable arm mechanism that can extend and retract. During charging operations, the movable arm extends to provide adequate support and withstand operational loads. During normal driving, the movable arm retracts to minimize space requirements and accommodate narrow front compartment designs.
Solution Approach 2:
The charging system is divided into separable components: the charging port, the movable arm, and the bracket structure. This segmentation allows the charging port to be positioned optimally during charging operations while enabling the movable arm to retract when not in use, effectively managing space constraints in the front compartment.
2Ease of operation
If the charging port is positioned at a low location to facilitate charging operations, then charging access is improved, but the charging port becomes more vulnerable to impact loads from front collisions
Solution Approach 1:
The charging port position is dynamically adjustable through the movable arm mechanism. During charging operations, the movable arm extends to position the charging port at an ergonomically accessible height and angle. During normal driving conditions, the movable arm retracts to position the charging port higher and more protected within the front compartment, reducing vulnerability to impact loads from front collisions.
3Ease of operation
If the charging port is tilted rearward to facilitate charging operations, then charging access is improved, but the length of the structure in the vehicle front-rear direction increases
Solution Approach 1:
The charging port's tilt angle and position are dynamically adjusted using the movable arm mechanism. When charging operations are required, the movable arm extends and positions the charging port at an optimal tilted angle for ease of access. When not in use, the movable arm retracts, effectively reducing the projected length of the charging port structure in the vehicle front-rear direction and minimizing space occupation in the front compartment.
Data Source
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AI summary
[Problem to be Solved] To ensure the rigidity of a charging unit in a vehicle front part and to reduce the occurrence of failures of a charging unit. [Solution] A front structure of an electric vehicle includes a dash side member 20 extending in a front-rear direction, an upper bumper crossmember 50 connecting vehicle body frames on opposite sides, and a connector receiver 30. The connector receiver 30 includes a charging unit 32 into which a charging connector is insertable from the front of the upper bumper crossmember 50, and a bracket 40 joined to the upper bumper crossmember 50 extends rearward from the upper bumper crossmember 50 and is joined to a dash panel 10. The charging unit 32 is provided in a front part of the bracket 40.