Fuel Cell Vehicle Power Module Mounting and Wiring Integration
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Solution Overview
Problem
In fuel cell vehicles, the connection of power control units and compressors for air conditioners using power wiring often results in inefficiencies and increased costs due to the need for extra connectors and complex wiring configurations, particularly when mounting high voltage apparatuses and fuel cells in the engine room.
Innovation Solution
A fuel cell vehicle design where the high voltage apparatus for the fuel cell is positioned in front or behind the cabin, with the compressor integrated underneath, and connected to the power control unit using a single power wiring, allowing for improved work efficiency and cost reduction by eliminating the need for extra connectors and simplifying the wiring process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a two-split wiring configuration is used to connect the power control unit and compressor at intermediate positions, then workability of connecting the power control unit and compressor is improved, but two extra connectors are required which increases weight and cost
Solution Approach 1:
The patent merges the power wiring connection into a single integrated wiring system that connects the power control unit and compressor directly, eliminating the need for two separate wiring paths and intermediate connectors. This consolidation reduces the number of connectors from two to one, thereby reducing weight while maintaining workability during assembly.
2Ease of operation
If a two-split wiring configuration is used to connect the power control unit and compressor at intermediate positions, then workability of connecting the power control unit and compressor is improved, but two extra connectors are required which increases cost
Solution Approach 1:
The patent consolidates the wiring system into a single integrated configuration, reducing the component count from two connectors to one. This merging approach lowers manufacturing costs by reducing parts inventory, assembly steps, and quality inspection requirements while preserving the improved workability benefits.
3Adaptability or versatility
If the compressor is disposed under the internal combustion engine and connected to the power control unit by power wiring, then the compressor can be positioned in a standard location, but difficulties related to work space occur during connection
Solution Approach 1:
The patent transitions from a horizontal wiring approach (which requires lateral work space) to a vertical wiring arrangement where the power wiring extends downward from the power control unit to the compressor positioned underneath. This dimensional change in wiring routing maintains standard compressor positioning while eliminating work space constraints during connection.
4Ease of operation
If the power control unit and compressor are connected by power wiring before the internal combustion engine is mounted, then work space difficulties are avoided, but the internal combustion engine must be mounted in a state where both components are simultaneously held, decreasing work efficiency
Solution Approach 1:
The patent applies preliminary action by pre-connecting the power wiring to the compressor before engine mounting, allowing the compressor to be positioned and wired in advance. This preliminary preparation eliminates the need for simultaneous handling during engine installation, thereby avoiding work space difficulties while maintaining high work efficiency through sequential assembly.
Data Source
AI summary
A fuel cell vehicle includes a high voltage apparatus for a fuel cell, a compressor for an air conditioner disposed under the high voltage apparatus for the fuel cell and constituting a module integrated with the high voltage apparatus for the fuel cell, and a power control unit separated from the high voltage apparatus for the fuel cell, disposed at a vehicle body over the compressor and configured to control an operation of a motor. The compressor and the high voltage apparatus for the fuel cell are connected by a single power wiring.