EV Battery Harness Mounting Guide for Collision Protection
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Solution Overview
Problem
In electric vehicles with high tension cables penetrating the floor panel, collisions can cause damage to the cables due to the floor panel moving and contacting the tubular wall protecting the cables, which is a concern for rear, lateral, and front collisions.
Innovation Solution
The electric vehicle design includes a mounting portion with a guide portion for the electric power supply harness that directs it obliquely downward through an opening in the floor panel, and a fixing portion with a bolt to prevent contact between the floor panel and the harness during collisions, along with a mounting pedestal for the three-phase wire harness to minimize damage and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the high tension cable is protected with a tubular wall protruding from the floor penetrating hole, then the cable is protected from damage, but during rear collision the floor panel moves forward and the tubular wall contacts the high tension cable causing damage
Solution Approach 1:
The patent introduces a guide portion as an intermediary element between the floor panel opening edge and the high tension cable. This guide portion redirects the movement path of the opening edge during collision, causing it to move obliquely downward instead of directly forward, thereby preventing contact with the cable while maintaining the protective function
Solution Approach 2:
The patent changes the movement dimension of the floor panel opening edge by adding a downward oblique component to its collision path. The guide portion transforms the purely horizontal collision movement into a two-dimensional path with both horizontal and vertical components, preventing the edge from contacting the cable
2Adaptability or versatility
If the electrical component unit is positioned at a different location from the battery and motor, then system layout flexibility is improved, but the high tension cable must penetrate the floor panel creating collision vulnerability
Solution Approach 1:
The mounting portion with guide portion acts as an intermediary structure that enables the cable penetration requirement while protecting against collision damage. It mediates between the need for component separation and the need for cable protection during collision
Data Source
AI summary
An electric vehicle comprises: a battery installed under a floor panel; an electrical component unit installed above the floor panel and behind the battery; an electric power supply harness connecting the electrical component unit and the battery; and a motor driven by electric power from the battery. A mounting portion where the harness is mounted is provided on a bottom surface of the electrical component unit. The mounting portion faces an opening of the floor panel, and the mounting portion has a fixing portion on the front side thereof in the longitudinal direction of the vehicle, the fixing portion allowing the harness to be fixed thereto in such a manner as to be routed toward the front of the vehicle. An inclined surface inclined downwardly toward the front of the vehicle is provided on the back side of the mounting portion in the longitudinal direction of the vehicle.