EV Power Converter Grounding Structure for HV Connector Protection
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Solution Overview
Problem
There is a need for effective grounding from a high voltage connector to a vehicle body in electric vehicles equipped with electrical power converters, as existing technologies do not adequately ensure reliable electrical conductivity and protection against external forces.
Innovation Solution
An electric vehicle configuration that includes a conductive case for the electrical power converter, a bracket for fixing it to the vehicle body, a metal plate connected via a ground line to the high voltage connector, and a resin cover with fastening members to secure the metal plate, ensuring proper grounding and protection against collision damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ground line is linked to the high voltage connector and then to the vehicle body via metal plate and bracket, then grounding reliability is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple grounding components (metal plate, bracket, fastening members) into an integrated grounding system where the metal plate is fixed to the resin cover which is already attached to the case, and the bracket fixes the case to the vehicle body. This merging approach ensures reliable grounding path while avoiding excessive complexity by using existing structural elements for multiple purposes.
Solution Approach 2:
The ground line acts as an intermediary element connecting the high voltage connector to the metal plate, which in turn connects to the vehicle body through the bracket and case. This intermediary grounding path ensures electrical isolation is maintained while providing a reliable grounding connection when needed.
2Strength
If the metal plate is fixed to the resin cover with multiple fastening members, then the protection against external forces is improved, but the number of fastening points increases
Solution Approach 1:
The patent merges the fastening function by using fastening members that simultaneously secure the metal plate to the resin cover and attach the resin cover to the case. This combined fastening approach provides strong protection against external forces while minimizing the number of separate fastening operations and points required.
Solution Approach 2:
The resin cover serves multiple functions: it protects the cable, provides a mounting surface for the metal plate, and acts as a structural element fixed to the case. The fastening members exploit this multi-functionality by securing both the metal plate and the resin cover attachment in a single fastening operation, reducing overall complexity.
3Object-affected harmful factors
If the resin cover protects the cable and is fixed to the case, then the cable protection is improved, but the ease of manufacture decreases
Solution Approach 1:
The patent combines the cable protection function and the mounting function into a single resin cover component. The fastening members simultaneously secure the metal plate and attach the resin cover to the case in one operation, improving ease of manufacture while maintaining comprehensive cable protection and structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides reliable grounding from the high voltage connector to the vehicle body, enhancing electrical conductivity and protecting against external forces, while maintaining the structural integrity of the resin cover and reducing the number of fastening points.
Implementation Method 1
The ground line is configured to link the high voltage connector and the metal plate. The metal plate is fixed on the resin cover such that the metal plate conducts with the vehicle body via the case and the bracket.
Data Source
AI summary
An electric vehicle includes an electrical power converter including a case that has electrical conductivity, a cable that connects the electrical power converter and a battery, a high voltage connector that is provided at an end portion of the cable, and that is detachably mountable to the electrical power converter, a resin cover that is fixed to the case, and that protects the cable, a bracket that is fixed to the case, and that fixes the electrical power converter to a vehicle body of the electric vehicle, a metal plate that conducts with the vehicle body via the case and the bracket, and that is fixed on the resin cover, and a ground line that links the high voltage connector and the metal plate.