EV Harness Routing Structure for Electromagnetic Noise Reduction
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Solution Overview
Problem
In electric vehicles, resonance currents generated in wire harnesses increase when inverter devices are driven, leading to elevated electromagnetic noise, which can cause malfunctions in electronic devices.
Innovation Solution
A harness routing structure where the length of the wire harness between the battery and inverter is an integer multiple of a specific parameter λa (0.462λ ≤ λa ≤ 0.538λ), incorporating a winding portion and a fixing member that includes a bending flange portion, supports the winding portion without overlapping with the power train, and covers the connecting portion to minimize electromagnetic noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire harness length is increased to route around the power train, then the harness can avoid interference with moving components, but the electromagnetic noise emission increases due to resonance current
Solution Approach 1:
The patent applies parameter changes by precisely controlling the wire harness length to be an integer multiple of λa (where 0.462λ ≤ λa ≤ 0.538λ, and λ is the rising wavelength of noise current). This specific parameter adjustment minimizes resonance current and reduces electromagnetic noise emission while maintaining the harness routing that avoids power train interference.
2Object-generated harmful factors
If the wire harness length is adjusted to minimize electromagnetic noise, then noise emission is reduced, but the harness routing becomes more complex
Solution Approach 1:
The patent resolves the routing complexity by utilizing the vertical dimension - introducing a winding portion that extends in the vehicle height direction. This allows the harness to achieve the required length adjustment for noise minimization without creating complex horizontal routing paths, thereby reducing overall routing complexity while meeting electromagnetic noise requirements.
3Object-generated harmful factors
If a winding portion is added to adjust harness length, then electromagnetic noise is reduced and flexibility is improved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the wire harness into distinct functional segments: a fixed length portion and a winding portion. The winding portion is specifically designed as a separate adjustable element that can be independently configured to achieve the optimal length (integer multiple of λa), thereby reducing electromagnetic noise while keeping the overall structure manageable and not excessively complex.
4Reliability
If the winding portion is positioned to avoid power train overlap, then electrical safety is maintained, but the available space for routing is reduced
Solution Approach 1:
The patent resolves the space constraint by transitioning the winding portion from horizontal routing to the vertical dimension (vehicle height direction). This allows the harness to achieve the necessary length adjustment for electrical safety and noise reduction without occupying additional horizontal space that would conflict with power train components, effectively utilizing unused vertical routing space.
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
This configuration reduces electromagnetic noise to a specified value, prevents malfunctioning, allows for easy length adjustment, enhances electrical safety, improves manufacturing efficiency, and increases the rigidity of the damper housing, thereby enhancing the vehicle's riding comfort and aerodynamic performance.
Implementation Method 1
resonance currents generated in wire harnesses increase when inverter devices are driven and thus the electromagnetic noise emitted from the wire harnesses increases
Data Source
AI summary
A harness routing structure for an electric vehicle includes a battery, an inverter device, and a harness configured to connect the battery and the inverter device. A length L of the harness between a battery fixing end of the battery to which the harness is fixed and an inverter fixing end of the inverter device to which the harness is fixed is an integer multiple of a parameter λa associated with a rising wavelength λ when the inverter device is driven, and the parameter λa satisfies 0.462λ≤λa≤0.538λ.