Fuel Cell Unit Control Device Mounting and Waterproofing
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Solution Overview
Problem
The existing fuel cell units face challenges in assembling due to the need for high waterproof cables connecting the cell monitor and control device, and the placement of the control device inside the fuel cell unit can lead to insufficient fixation due to thermal expansion and contraction stresses.
Innovation Solution
A fuel cell unit configuration where the control device is placed in a separate second case fixed to the upper surface of the first case containing the fuel cell, with a connector portion protruding from the first case and an insertion space in the second case for easy connection of the communication cable, reducing assembly difficulties and thermal stress effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control device is placed inside the fuel cell unit housing, then the cable waterproof requirement is reduced, but assembly difficulty increases due to the need to connect cables before mounting the cover
Solution Approach 1:
The housing is divided into a cover and a base, with the connector portion protruding from the base and the connector opening provided in the cover. This segmentation allows the cable connection to be established after the cover is mounted, eliminating the need for pre-assembly of cables before cover installation, thus reducing assembly difficulty while maintaining waterproof protection.
2Ease of manufacture
If the control device is fixed relative to the fuel cell like the cell monitor, then assembly is simplified, but fixation becomes insufficient due to thermal expansion and contraction stresses
Solution Approach 1:
The control device is extracted from direct fixation to the fuel cell and instead mounted on the cover. This separation isolates the control device from the thermal expansion and contraction stresses of the fuel cell, ensuring stable fixation without compromising assembly simplicity. The connector portion protruding from the base and connecting through the cover opening maintains electrical connection while accommodating thermal movements.
3Reliability
If high waterproof cables are used to connect the cell monitor and control device, then waterproof property is improved, but device cost increases
Solution Approach 1:
The connector portion protruding from the base and the connector opening in the cover act as intermediaries, allowing the use of standard cables instead of expensive high-waterproof cables. The cover itself serves as the waterproof barrier, eliminating the need for specialized waterproof cable treatments or constructions, thus reducing device cost while maintaining adequate waterproof protection.
Data Source
AI summary
The fuel cell unit comprises a fuel cell including a cell stack with a plurality of stacked cells; a cell monitor which monitors one or more of the plurality of stacked cells; a control device connected with the cell monitor via a communication cable; a first case which places the fuel cell therein; and a second case which places the control device therein and fixed to an upper surface of the first case. The cell monitor includes a connector portion protruded from the first case and provided with a connection connector which is connected with a communication connector of the communication cable. The second case includes an insertion space for receiving the connector portion when the second case is fixed to the first case and further includes a connector opening in a surface opposed to the connection connector when the connector portion is inserted in the insertion space.