EV Lower Structure Layout for Inclined Converter Clearance
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Solution Overview
Problem
In electric vehicles, high-voltage components are prone to contact with the front subframe during collisions due to their positioning under the floor panel, making it difficult to connect harnesses and cooling pipes without increasing costs and complexity by adding protective members.
Innovation Solution
The high-voltage components are arranged in a vertically inclined position, with the front-end portion higher than the rear end of the side frame section, allowing the rear end to be lower than the adjacent vehicle component, thereby avoiding contact with the front subframe and securing connection space without additional protective members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage components are arranged under the floor panel in a conventional position, then the components can be easily accessed for installation, but the components are prone to contact with the front subframe during collisions
Solution Approach 1:
The high-voltage component is arranged in an inclined state along the lower surface of the floor panel, changing from a conventional horizontal arrangement to a three-dimensional inclined configuration. This dimensional change allows the component to avoid contact with the front subframe during collisions while maintaining accessibility for harness and pipe connections, eliminating the need for additional protective members
2Ease of operation
If the high-voltage component is arranged at a lower position to allow harness connection, then connection work becomes easier, but the component becomes more vulnerable to contact with the front subframe
Solution Approach 1:
The high-voltage component is arranged with different local positions at different heights: the rear end portion is positioned lower to facilitate harness and pipe connections, while the front-end portion is positioned higher to avoid contact with the front subframe. This local quality differentiation allows simultaneous achievement of ease of connection and collision safety
3Reliability
If the high-voltage component is arranged in a vertically inclined position, then contact with the front subframe is avoided, but the component requires more complex attachment methodology
Solution Approach 1:
The attachment methodology is designed to accommodate the inclined arrangement of the high-voltage component, using dynamic positioning and flexible connection methods that adapt to the inclined configuration. This allows the component to be securely attached in its inclined state without requiring overly complex manufacturing processes
Data Source
AI summary
To simultaneously avoid contact with a front subframe and secure a connection space for a harness, a front subframe has a right and left pair of side frame sections, each of which is located in front of and below a dashboard. A converter and a vehicle component are provided behind a rear end portion of one of the side frame sections. The converter is arranged along a lower surface of a floor panel, and the vehicle component is arranged adjacent to rear of the converter. The converter is arranged in a vertically inclined state, a front-end portion of the converter is located higher than the rear end portion of the side frame section, and a rear end portion of the converter is located lower than the vehicle component.