EV Power Supply Mounting with Perpendicular Fasteners
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Solution Overview
Problem
Existing electric and hybrid vehicle power supply systems face challenges in securely mounting power modules to prevent over-compression and stress from vibrations, which can lead to damage and fatigue in electrical connections and seal joints.
Innovation Solution
The power supply system incorporates a housing with inwardly and outwardly protruding tabs and fasteners that engage perpendicularly to secure the power assembly, reducing the risk of over-compression and stress by orienting fasteners at an angle perpendicular to the longitudinal direction, and includes a cooling manifold for thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power module is securely mounted to the housing, then the reliability is improved, but the device complexity increases due to additional mounting structures
Solution Approach 1:
The housing is segmented with multiple inwardly protruding tabs distributed at different locations, and the power module has corresponding outwardly protruding tabs. This segmentation allows the mounting function to be distributed across multiple discrete attachment points rather than requiring a single complex mounting structure, thereby improving reliability through redundant attachment points while keeping each individual tab simple in design.
Solution Approach 2:
The outwardly protruding tabs on the power module are designed to fit within or engage with the inwardly protruding tabs on the housing, creating a nested attachment arrangement. The fasteners further nest by engaging both tabs simultaneously. This nested configuration achieves secure mounting through a compact, space-efficient structure that minimizes overall complexity while ensuring reliable connection.
2Reliability
If the fasteners are oriented perpendicular to the longitudinal direction, then the stress on electrical connections and seal joints is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The fasteners are deliberately oriented perpendicular to the longitudinal direction of the power module, creating an asymmetric mounting arrangement relative to the module's primary axis. This asymmetric orientation is specifically designed to minimize stress transmission to the electrical connections and seal joints, which are typically aligned with the longitudinal direction. The tab positions are asymmetrically distributed to facilitate this perpendicular fastener orientation while maintaining manufacturing feasibility.
3Reliability
If multiple fasteners are used to secure the power assembly, then the mounting reliability is improved, but the device complexity increases
Solution Approach 1:
The mounting system is segmented into multiple discrete fasteners, each engaging a specific pair of inwardly and outwardly protruding tabs. This segmentation distributes the mounting function across multiple simple, identical components rather than requiring a single complex mounting mechanism. Each fastener performs the same basic function, simplifying individual component design while achieving cumulative reliability through multiple attachment points.
Solution Approach 2:
The design changes the mounting parameter from a single complex attachment mechanism to multiple simple fasteners. By changing the mounting approach from one large securement point to several smaller ones, the system achieves improved reliability through redundancy and distributed loading, while each individual fastener remains simple in design and easy to install.
Data Source
AI summary
An electric vehicle power supply includes a housing, a power supply, and a plurality of fasteners. The housing defines an internal cavity and has inwardly protruding tabs that extend into the cavity. The power assembly has a front cover and an end cover. The power assembly also has an array of electrical switching units arranged horizontally between the front and end covers. The front and end covers have outwardly protruding tabs. Each of the plurality of fasteners extend vertically, engage one inwardly protruding tab, and engage one outwardly protruding tab to secure the power assembly to the housing.