Insulating Cover for EV Control Unit Shock Hazard Protection
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Solution Overview
Problem
Existing control devices for electric and hybrid vehicles pose a risk of accidental contact with live parts when the housing cover is opened, as there is no effective protection to prevent exposure to electrical components.
Innovation Solution
An electrically insulating contact protection cover with projections and latching hooks that securely attach to the housing cover, allowing it to remain locked during maintenance while ensuring the protection cover can be easily released, thus preventing accidental contact with live components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the housing cover is opened for maintenance or service purposes, then accessibility to electrical components is improved, but the risk of accidental contact with live parts increases
Solution Approach 1:
A contact protection cover is introduced as an intermediary element between the housing cover and the electrical components. This protective cover remains attached to the housing cover when opened, creating a safe barrier that prevents direct contact with live parts while allowing maintenance personnel to work on the electrical components underneath.
Solution Approach 2:
The protective cover system is segmented into two functional parts: the contact protection cover that moves with the housing cover, and the electrical component covers that remain with the housing. This segmentation allows the protective function to be separated from the structural function, enabling the housing cover to be opened for maintenance while maintaining protection.
2Reliability
If the contact protection cover is strongly connected to the housing cover, then the protection cover remains secure during opening, but the protection cover cannot be easily separated for component access
Solution Approach 1:
The connection between the contact protection cover and housing cover is designed to be dynamic rather than fixed. The non-positive connection (recess and protrusion) allows the covers to be easily separated when needed, while the latching hooks provide automatic engagement during assembly, creating a system that adapts its connection strength based on the operational phase.
Solution Approach 2:
The latching hooks are pre-positioned on the contact protection cover to automatically engage with the housing cover during assembly. This preliminary positioning ensures that the protective cover is securely attached before the housing cover is opened, eliminating the need for separate fastening operations while maintaining reliability.
3Strength
If multiple connection methods are used to attach the contact protection cover, then the connection strength is improved, but the device complexity increases
Solution Approach 1:
Multiple connection functions are merged into a single integrated contact protection cover structure. The latching hooks and non-positive connection elements are combined in one component, eliminating the need for separate fasteners or attachment mechanisms. This merging maintains strong connection while reducing the number of discrete parts and assembly steps.
Data Source
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AI summary
The invention relates to a control unit for an electric vehicle or hybrid vehicle. The control unit has a housing enclosing a cavity. The housing has a housing lid and a housing opening, wherein the housing lid is designed to close the housing opening. According to the invention, the control unit has an electrically insulating shock hazard protection cover, which has at least one projection region extending transversely with respect to a surface of the shock hazard protection cover. The housing lid has at least one receptacle for the projection region, wherein the cutout is designed to retain the projection region in a force-locking manner. The shock hazard protection cover has at least one latching hook designed to latch in a positively locking manner, or additionally in a force-locking manner, with the housing or a part of the control unit in the interior of the housing which is connected to the housing.