Fuel Cell Casing Fastening for DC-DC Converter
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Solution Overview
Problem
In fuel cell vehicles, the narrow spaces above and below the protection bar make it difficult to ensure sufficient strength for fastening and fixing the fuel cell casing and boost converter, which are required to vibrate as a unit to match their natural frequencies, due to limited vertical space and the need for horizontal bolt insertion.
Innovation Solution
The fuel cell casing and boost converter are fastened and fixed with a horizontal fastening surface, allowing vertical bolt insertion and ensuring a larger fastening surface even in constrained spaces, with the first fastening part of the fuel cell casing and the second fastening part of the boost converter being vertically superimposed, facilitating alignment and secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the fuel cell casing and boost converter are fastened with a vertical fastening surface in narrow spaces above/below the protection bar, then the fastening can be performed in the constrained space, but the fastening surface area becomes insufficient and fastening strength is reduced
Solution Approach 1:
The patent transitions from a vertical fastening surface configuration to a horizontal fastening surface configuration by positioning the first fastening part on the rear surface of the fuel cell casing and the second fastening part on the front surface of the boost converter, enabling bolts to be inserted horizontally rather than vertically. This dimensional change allows sufficient fastening surface area to be achieved within the limited vertical space above or below the protection bar.
2Ease of operation
If bolts are inserted horizontally to fasten components in narrow spaces, then the fastening can be performed, but the operation becomes difficult and accessibility is reduced
Solution Approach 1:
The patent changes the bolt insertion direction from horizontal to vertical by reconfiguring the fastening parts to have vertical fastening surfaces. The first fastening part extends upward from the rear surface of the fuel cell casing, and the second fastening part extends upward from the front surface of the boost converter, allowing bolts to be inserted vertically from above, which greatly improves operational ease and accessibility.
3Reliability
If the fuel cell casing and boost converter are arranged in separate locations to avoid interference with the protection bar, then the protection bar function is maintained, but the electrical connection durability is compromised due to different vibration systems
Solution Approach 1:
The patent merges the fuel cell casing and boost converter into a single integrated assembly by fastening them together through the protection bar space. The first fastening part on the fuel cell casing and the second fastening part on the boost converter are connected with bolts, making the two components vibrate as a unified system with consistent natural frequencies, thereby improving electrical connection durability while maintaining protection bar functionality.
Data Source
AI summary
A protection bar is arranged between a fuel cell casing and a DC-DC converter in the left-right direction of a fuel cell vehicle. Two fastening surfaces, each being a part of the fuel cell casing, and an FDC flange, which is a part of the DC-DC converter, are fastened and fixed to each other, with one being vertically superimposed on the other, in a space above or below the protection bar.