Fuel Cell Vehicle Power Distribution Unit Harness Reduction

Solution Overview

Problem

Fuel cell vehicles require numerous high-voltage harnesses for connecting power-generation auxiliary machines to the power control unit, leading to increased vehicle weight and cost due to the need for additional machines and space for installation.

Innovation Solution

A fuel cell vehicle configuration that includes a power distribution unit on the electrical path between the storage battery and power control unit, which distributes electric power to power-generation auxiliary machines, reducing the number of high-voltage harnesses by using the storage battery as a power source and allowing direct connection between the power distribution and control units without additional harnesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If harnesses are used to connect power-generation auxiliary machines to the power control unit, then electrical connection is achieved, but the number of high-voltage harnesses increases leading to increased vehicle weight and cost

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the power distribution function with the power control unit by providing a connector on the power control unit that directly connects to the power distribution unit. This integration eliminates the need for separate harnesses to connect auxiliary machines to the power control unit, reducing vehicle weight while maintaining reliable electrical connections.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If harnesses are used to connect power-generation auxiliary machines to the power control unit, then electrical connection is achieved, but the number of high-voltage harnesses increases leading to increased cost

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the power distribution function with the power control unit by providing a connector on the power control unit that directly connects to the power distribution unit. This integration eliminates the need for separate harnesses to connect auxiliary machines to the power control unit, reducing vehicle weight while maintaining reliable electrical connections.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If additional machines are added to the electric system, then power-generation auxiliary machines can operate, but the device complexity increases

Engineering Contradiction:

Improvesystem adaptabilityVSAvoidelectric system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The power control unit is designed with a connector that serves multiple functions: it provides electrical connection for the power distribution unit and simultaneously enables connection points for power-generation auxiliary machines. This multi-functionality allows the system to accommodate various auxiliary machines without proportionally increasing system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 configuration reduces the number of high-voltage harnesses, lowering costs and increasing productivity by using the storage battery to supply power to auxiliary machines with adjusted voltage, while also enhancing safety and compactness by eliminating the need for additional harnesses and space, and minimizing the risk of damage during collisions.

Implementation Method 1

a fuel cell that generates electric power by electrochemical reaction is mounted

Methodology Applied

Scientific EffectElectrochemical reaction: Fuel Cell

Data Source

PatentUS10220723B2Fuel cell vehicle

Publication Date: 2019.03.05 TOYOTA JIDOSHA KK

AI summary

A fuel cell vehicle (1) includes: a fuel cell (11); a storage battery (17); a power control unit (10), electrically connected to the fuel cell (11) and the storage battery (17), for controlling electric power in the vehicle (1); a power distribution unit (16), provided on an electrical path between the storage battery (17) and the power control unit, for distributing the electric power from the storage battery; and power-generation auxiliary machines (15) which are electrically connected to the power distribution unit (16) and to which the electric power, distributed by the power distribution unit (16), is supplied for performing operation for electric power generation by the fuel cell (11). The power distribution unit (16) and the power control unit (10) are connected directly without use of a harness.