EV Mechatronic Unit Layout for Frontal Impact Protection
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Solution Overview
Problem
Existing electrified vehicles face challenges in protecting high-voltage auxiliaries such as the electric compressor and high-voltage heater during frontal collisions, as they are vulnerable to damage from impacts.
Innovation Solution
The vehicle design includes an inclined surface configuration where the mechatronic unit and integrated thermal unit surfaces face each other, allowing them to overlap and absorb impact forces during a collision, reducing the likelihood of damage by enabling surface-to-surface contact and upward movement of these auxiliaries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the auxiliary is installed in front of the mechatronic unit, then the auxiliary can be positioned in the available space, but the auxiliary becomes vulnerable to impact damage during frontal collisions
Solution Approach 1:
The patent introduces an inclined surface configuration that transforms the vertical dimension into a protective mechanism. When the auxiliary overlaps the mechatronic unit in the vehicle front view, the inclined surfaces create a three-dimensional protective arrangement where impact forces are redirected upward along the incline rather than directly onto the auxiliary components, effectively using spatial geometry to mitigate collision damage.
Solution Approach 2:
The patent converts the harmful impact force from frontal collisions into a beneficial protective mechanism. The inclined surfaces are designed so that during a collision, the impact force causes the auxiliary to move upward along the incline rather than being compressed or damaged, transforming the harmful collision energy into a protective displacement that prevents damage to the auxiliary components.
2Stress or pressure
If the mechatronic unit and auxiliary surfaces are configured as inclined surfaces, then impact load per unit area is reduced, but the structural complexity increases
Solution Approach 1:
The patent changes the geometric parameter of the surfaces from flat to inclined, specifically designing the inclined surfaces to ascend toward the rear side in the vehicle front-rear direction. This parameter change transforms the stress distribution during impact, reducing the load per unit area on the auxiliary by distributing the force over a larger surface area and redirecting it upward, while maintaining a relatively simple overall structure.
Data Source
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Figure 3
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AI summary
An electrified vehicle (30) includes: a battery (33); a mechatronic unit (300) including a motor (350) that is a motive power source and an electric power control device (310) configured to supply electricity from the battery (33) to the motor (350); and an auxiliary installed in front of the mechatronic unit (300) in a vehicle front-rear direction. The mechatronic unit (300) and the auxiliary are installed frontward of a vehicle cabin (46) in the vehicle front-rear direction. The auxiliary overlaps the mechatronic unit (300) as seen in a vehicle front view. At least one surface of a surface of the mechatronic unit (300) that faces the auxiliary and a surface of the auxiliary that faces the mechatronic unit (300) is an inclined surface that is inclined so as to ascend toward a rear side in the vehicle front-rear direction.