EV Electrical Unit Layout to Avoid Dash Panel Collision Interference
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Solution Overview
Problem
In small-sized electric vehicles, the narrow motor compartment leads to potential interference between the electrical unit and the dash panel or master cylinder during a collision, which can affect occupant safety.
Innovation Solution
The electrical unit is supported by upper mounts with varying rigidity, allowing it to pivot during a collision, preventing interference with the dash panel and master cylinder, and is positioned diagonally to minimize overlap with these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electrical unit is arranged side by side with the motor and gearbox in the narrow motor compartment, then the space utilization is improved, but the distance between the electrical unit and the dash panel becomes small, increasing the risk of interference during collision
Solution Approach 1:
The patent applies the dynamics principle by making the electrical unit movable rather than fixed. The electrical unit is configured to be movable in the vehicle width direction relative to the motor compartment, allowing it to dynamically adjust its position. This enables the electrical unit to retreat from the collision path when impact occurs, preventing interference with the dash panel and master cylinder while maintaining compact space utilization during normal operation
Solution Approach 2:
The patent applies segmentation by separating the electrical unit from the fixed motor compartment structure. The electrical unit is mounted on movable supports that allow independent movement, effectively segmenting the rigid assembly into movable and stationary parts. This segmentation enables the electrical unit to move independently during collision to avoid interfering with safety-critical components
2Productivity
If the electrical unit is positioned closer to the dash panel to maximize space, then the productivity of the motor compartment is improved, but the harmful effect of potential interference with the master cylinder or dash panel during collision increases
Solution Approach 1:
The electrical unit is designed with movable supports that enable it to dynamically retreat in the vehicle width direction during collision. This dynamic capability allows the electrical unit to maintain close proximity to the dash panel for space efficiency while automatically moving away when collision forces are applied, eliminating the harmful interference effect
Solution Approach 2:
The patent applies preliminary anti-action by pre-configuring the movable support mechanism that counteracts the potential harmful movement of the electrical unit during collision. The movable supports are designed to automatically resist collision forces and guide the electrical unit away from the dash panel and master cylinder, preventing interference before it can occur
Data Source
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AI summary
An electric vehicle 1 is equipped with a dash panel 2, a master cylinder 3, which is arranged on the motor compartment R1 side and the driver's seat side of the dash panel 2 and which is connected to a brake pedal BP in a vehicle passenger compartment R2, and an electrical unit 4 that includes an inverter 41, a motor 42, and a gearbox 43 arranged side by side in the motor compartment R in the left-right direction of the vehicle. The electrical unit 4 is disposed in front of and below the master cylinder 3 in the motor compartment R1 in the front-rear direction of the vehicle.