Saddle-Type Electric Vehicle High Voltage Wire Routing
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Solution Overview
Problem
Existing saddle-type electric vehicles face challenges in optimizing the disposition of high voltage electric wires to achieve a compact size while maintaining protective performance, as disclosed in Japanese Unexamined Patent Application No. 2012-96594 does not clearly address the protection and placement of these wires.
Innovation Solution
The proposed configuration includes a battery and motor with high voltage electric wires disposed in a gap between a reduction gear and the battery, which also serves as protection from external impacts, and the wires are oriented in a way that reduces the vehicle's size by being sandwiched between the reduction gear and battery, with an inverter positioned below the motor and wires oriented upward/downward to minimize length and enhance protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high voltage electric wires are made thick to allow large current flow, then current carrying capacity is improved, but vehicle size increases
Solution Approach 1:
The high voltage electric wire is routed through the dead space in the forward/rearward direction between the reduction gear and battery, utilizing the third dimension (depth) rather than only horizontal or vertical spaces. This allows the thick wire to be accommodated without increasing the vehicle's external dimensions.
2Volume of moving object
If high voltage electric wires are disposed in dead space between reduction gear and battery, then vehicle size is reduced, but protection of wires from external impacts deteriorates
Solution Approach 1:
The reduction gear and battery, which are rigid components, are positioned to sandwich the high voltage electric wire. These components that could potentially cause harm actually serve as protective barriers against external impacts such as flying stones, converting potential harmful elements into protective structures.
Solution Approach 2:
The dead space between the reduction gear and battery serves multiple functions: it accommodates the high voltage electric wire routing and simultaneously provides structural protection for the wire. The reduction gear and battery both perform their primary functions while also acting as protective enclosures for the wire.
3Ease of manufacture
If high voltage electric wire is routed horizontally at outer side of motor, then connection to inverter is simplified, but wire length increases
Solution Approach 1:
The wire routing changes from a horizontal path at the outer side of the motor to a path that extends in the forward/rearward direction through the dead space between the reduction gear and battery, then connects downward to the inverter. This three-dimensional routing optimizes wire length while maintaining manufacturing feasibility.
Data Source
AI summary
An electric bicycle includes a battery, a high voltage electric wire extending from the battery, a motor driven by electricity supplied from the battery, and a reduction gear configured to reduce a speed of output of the motor. The battery is disposed in front of and above the motor. The reduction gear is disposed outside the motor in a vehicle width direction. The high voltage electric wire is disposed in a gap between the reduction gear and the battery in a forward/rearward direction at outer side of the motor in the vehicle width direction.