Vehicle Frame Rail Routing Electrical Distribution System
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Solution Overview
Problem
Existing electrified vehicles face challenges in efficiently routing and shielding their electrical distribution systems, leading to increased costs and complexity due to the need for separate electromagnetic interference (EMI) shielding and packaging difficulties.
Innovation Solution
The electrical distribution system is routed at least partially through a vehicle frame rail, utilizing the rail as an EMI shield and allowing for the use of less expensive components like unshielded electrical cables or bus bars, which are assembled within the rail for easier packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If separate EMI shielding is used for electrical cables, then electromagnetic interference protection is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the EMI shielding function with the frame rail structure itself. The frame rail is designed to enclose the electrical cable, and the metallic rail inherently provides EMI shielding. This merges the structural support function with the EMI protection function into a single integrated component, eliminating the need for separate shielding materials or structures.
Solution Approach 2:
The frame rail serves multiple functions simultaneously: it provides structural support for the vehicle, acts as a mounting structure for electrical components, and provides EMI shielding for the electrical cables routed through it. This multi-functionality reduces the overall number of components needed and simplifies the electrical distribution system packaging.
2Object-affected harmful factors
If separate EMI shielding is used for electrical cables, then electromagnetic interference protection is improved, but manufacturing cost increases
Solution Approach 1:
The EMI shielding function is merged into the frame rail structure, which is already a necessary component of the vehicle. By utilizing the inherent EMI-shielding properties of the metallic frame rail and routing cables through its enclosed space, the patent eliminates the need for additional shielding materials (such as ferrite beads, shielding tapes, or separate enclosures), thereby reducing manufacturing costs.
Solution Approach 2:
The frame rail provides its own EMI shielding capability through its metallic construction and enclosed geometry. The structure serves itself by providing protection to the cables routed through it without requiring external shielding components. This self-service approach reduces the bill of materials and assembly complexity.
3Ease of operation
If electrical distribution system is routed outside the frame rail, then installation flexibility is improved, but packaging efficiency and EMI shielding decrease
Solution Approach 1:
The electrical cable is nested within the frame rail structure. The cable routing is integrated into the existing frame rail geometry, utilizing the space already defined by the vehicle's structural components. This nesting approach improves packaging efficiency by utilizing otherwise wasted space and eliminates the need for separate cable trays or external routing structures.
4Object-affected harmful factors
If shielded electrical cables are used, then EMI protection is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
Instead of making the cable itself shielded (which adds complexity and cost to the cable assembly), the patent inverts the approach by making the surrounding environment (the frame rail enclosure) provide the shielding. This shifts the EMI protection function from the cable to the structural component, simplifying the cable design while maintaining protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs, simplifies packaging, and eliminates the need for separate EMI shielding, while maintaining effective power distribution between components like battery packs and motors within electrified vehicles.
Implementation Method 1
the rail acts as an electromagnetic interference (EMI) shield
Data Source
AI summary
A motor vehicle according to an exemplary aspect of the present disclosure includes, among other things, a frame including a rail and an electrical distribution system routed at least partially through the rail. A method is also disclosed.