FCEV Modular Parts Arrangement for NVH and Assembly
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Solution Overview
Problem
The existing arrangement of fuel cell system and drive motor components in fuel cell electric vehicles (FCEVs) limits available space, complicates assembly and maintenance, and degrades performance due to suboptimal installation positions and arrangements, leading to issues with noise, vibration, harshness (NVH), and impact absorption.
Innovation Solution
A modularized parts arrangement structure for FCEVs, where the fuel cell stack, thermal management system, hydrogen supply device, air humidifier, air blower, drive motor, decelerator, inverter, electrical junction box, air conditioner compressor, and water pump are optimally positioned and configured within the engine compartment to improve assembly efficiency, maintenance accessibility, and NVH performance, while reducing material costs and increasing impact absorption space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuel cell system and drive motor parts are installed within the FCEV, then the vehicle can operate with electric power generated by the fuel cell, but the available vehicle space is limited and parts cannot be arranged at optimal positions
Solution Approach 1:
The patent divides the engine compartment into multiple zones (upper end, lower end, front end, sides) and segments the arrangement of different parts accordingly. The fuel cell stack is positioned at the upper end, drive motor at the lower end, and other components are distributed to specific zones, optimizing space utilization while maintaining operational performance.
2Ease of manufacture
If parts are arranged in limited vehicle space, then all parts can be installed, but the ability to assemble and maintain parts decreases
Solution Approach 1:
The patent applies local quality by positioning maintenance-requiring parts (air conditioner compressor, water pump) at accessible locations within the engine compartment. The air conditioner compressor is installed at the side of the drive device facing the engine compartment opening, and the water pump is positioned at the front end, both allowing easy access for maintenance while maintaining compact overall arrangement.
3Area of stationary object
If parts are positioned at non-optimal locations, then space constraints are met, but NVH performance and cooling performance deteriorate
Solution Approach 1:
The patent utilizes three-dimensional spatial arrangement by positioning the fuel cell stack vertically at the upper end and the drive motor at the lower end, creating a vertical distribution of components. This vertical arrangement, combined with horizontal positioning of auxiliary components, optimizes NVH performance and cooling efficiency while maximizing space utilization in the engine compartment.
Data Source
AI summary
A parts arrangement structure of a fuel cell electric vehicle (FCEV) is provided. The structure improves ease of assembly and maintenance of parts, by efficiently arranging and modularizing a fuel cell system, a drive device, and some of electric parts, which are installed within the FCEV.