Electric Vehicle Circuit Case Positioning for Collision Protection
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Solution Overview
Problem
The control circuit in electric vehicles is prone to damage during collisions due to the application of large loads when the circuit case collides with rear body constituents, leading to difficulties in electrical control.
Innovation Solution
The circuit case is positioned on the front side of the rear crossmember in a top view, allowing the rear crossmember to collide with rear body constituents first, reducing the load on the circuit case, and a recess on the rear crossmember protects the wiring, while a resin cover protruding forward absorbs impact instead of the metal circuit case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the circuit case is positioned behind the rear crossmember, then the control circuit is protected from direct collision, but the circuit case is more likely to collide with rear body constituents during front collision, causing damage
Solution Approach 1:
The patent positions the circuit case in a specific spatial relationship relative to the rear crossmember - specifically, the circuit case is located such that its rear surface is positioned behind the rear surface of the rear crossmember in the vehicle width direction, but extends forward beyond the rear crossmember in the vehicle length direction. This multi-dimensional positioning allows the rear crossmember to act as a shield during front collisions while preventing the circuit case from directly contacting rear body constituents.
Solution Approach 2:
The rear crossmember serves as an intermediary protective element between the circuit case and rear body constituents. During front collision, the rear crossmember deforms and absorbs energy, preventing direct contact between the circuit case and rear body constituents, thereby reducing collision damage to the circuit case.
2Reliability
If the circuit case is made of metal, then the control circuit is well-protected, but the circuit case itself may sustain damage during collision
Solution Approach 1:
The patent employs a composite protective structure where the circuit case is made of metal material providing inherent protection to the control circuit, while the positioning strategy uses the deformable rear crossmember (typically made of different material properties) to absorb collision energy. This composite approach leverages the strengths of different materials - the metal circuit case protects the circuit, while the crossmember structure absorbs impact energy.
Data Source
AI summary
An electric vehicle may include: a body comprising a compartment on a front side of a cabin; a component frame located in the compartment, and connected to the body; and a circuit case located on the component frame, comprising therein a control circuit configured to control a traction motor, and constituted of metal. The component frame may comprise: a plurality of crossmembers extending along a vehicle left-right direction; and a connection member connecting the plurality of crossmembers to each other. The plurality of crossmembers may comprise a rear crossmember which is a rearmost crossmember of the plurality of crossmembers. The circuit case may be on the front side of a rear end of the rear crossmember in a top view.