EV High-Voltage Wire Support Structure for Bend Radius Protection
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Solution Overview
Problem
In electric vehicles with beam axles, the relative movement between the inverter and the electric motor poses challenges for wire protection, as high loads and limited space complicate inverter mounting, and existing solutions fail to adequately protect wires from damage due to bending, impact, and strain.
Innovation Solution
A wire protection system with sub-assemblies featuring pivoting joints, strain relief components, and cable shrouds that limit wire movement and maintain a minimum bend radius, providing impact protection and strain relief at fixed connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inverter is mounted to the body or frame of the vehicle, then the inverter is protected from damage due to beam axle movement and high loads, but three heavy gauge wires are required to transmit power from the inverter to the motor and these wires are vulnerable to damage from bending, impact, and strain
Solution Approach 1:
A wire protection system is introduced as an intermediary component between the inverter and motor. This system includes a wire protection assembly with a first end near the inverter and a second end near the motor, along with multiple links that form a protective chain. The protection system mediates the harmful effects of beam axle movement on the wires by providing physical protection against bending, impact, and strain while still allowing necessary relative motion.
Solution Approach 2:
The wire protection system provides beforehand cushioning by pre-positioning protective elements along the wire path. The links in the wire protection assembly are arranged to anticipate and absorb impact loads before they can damage the wires. The system includes features like bend radius maintainers and impact absorbers that are预先 positioned to protect against anticipated harmful effects during beam axle movement.
2Adaptability or versatility
If the wires have enough slack to allow motion between the fixed inverter and the moving beam axle, then the wires can accommodate relative movement, but the wires become vulnerable to damage from excessive movement and bending
Solution Approach 1:
The wire protection system employs dynamic elements that can move and adapt to the relative motion between the inverter and beam axle. The links in the protection assembly are designed to pivot and flex, allowing the system to dynamically accommodate changes in distance and angle while maintaining wire protection. This dynamic design enables the system to adapt to various positions during suspension travel without compromising wire integrity.
Solution Approach 2:
The wire protection assembly incorporates flexible protective elements that can bend and flex to accommodate motion. The links are designed with appropriate flexibility to allow necessary movement while maintaining structural protection. This flexible design enables the protection system to adapt to the dynamic motion requirements while preventing excessive bending and strain on the wires.
3Ease of operation
If the beam axle moves extensively relative to the vehicle frame during operation, then the suspension can absorb road impacts, but the wires experience extensive motion that can result in damage
Solution Approach 1:
The wire protection system is segmented into multiple discrete links that form a protective chain between the inverter and motor. This segmentation allows each link to independently move and absorb motion, while collectively providing continuous protection for the wires. The segmented design enables the protection system to accommodate extensive beam axle movement without transmitting all the motion directly to the wires, thereby preventing damage from bending and strain.
Data Source
AI summary
A flexible wire support structure extends between an axle and an inverter for an electric vehicle. The inverter is fixed relative to the vehicle body and the axle is moveable relative to the inverter during vehicle use. A wire extends between the inverter and the axle through a channel defined by the wire support structure. The wire support structure is attached at opposite ends to a first and second support structure, each of which allow pivoting of the flexible wire support structure in response to movement of the axle relative to the inverter. The wire support structure has a limited bend radius in response to movement of the axle, and blocks the wire extending within the support structure from being bent to a tight radius, thereby protecting the wire.