Generator-Inverter Harness Layout for Hybrid Vehicle Vibration Isolation
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Solution Overview
Problem
The existing hybrid electric vehicle systems experience significant vibration transmission from the internal combustion engine to the inverter due to thick, short, and straight wiring harnesses, leading to larger inverter sizes required for vibration resistance.
Innovation Solution
A hybrid electric vehicle design where the wiring harness connecting the generator to the inverter is routed in a curved path with different exit directions from the generator and inverter housings, allowing the harness to flex and absorb vibrations, thereby reducing vibration transmission and enabling a more compact system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the wiring harness is routed straight and kept short to connect the generator and inverter, then the electrical connection is simple and direct, but vibrations from the internal combustion engine are transmitted to the inverter, requiring larger vibration-resistant components
Solution Approach 1:
The wiring harness is routed in a curved path rather than a straight line, extending along the outer periphery of the engine room. This curvature allows the harness to flex and absorb vibrations from the internal combustion engine, preventing direct transmission to the inverter while maintaining electrical connectivity.
Solution Approach 2:
The wiring harness is positioned to extend in multiple directions and dimensions, specifically along the outer periphery of the engine room, rather than taking the shortest straight path. This spatial arrangement increases the harness length and creates vibration-absorbing loops that mitigate engine vibrations reaching the inverter.
2Power
If the wiring harness is made thick to handle high-voltage AC three-phase power, then the power transmission capability is sufficient, but the harness becomes rigid and transmits vibrations more effectively to the inverter
Solution Approach 1:
The thick wiring harness is routed in a curved path along the outer periphery, which introduces flexibility through bending. This curvature allows the rigid thick harness to absorb vibrations while maintaining its power transmission capability for high-voltage AC three-phase power.
Solution Approach 2:
The curved wiring harness acts as an intermediary element between the vibration source (internal combustion engine) and the sensitive component (inverter). By positioning the harness to extend along the outer periphery, it serves as a vibration-absorbing medium that protects the inverter while transmitting electrical power.
3Reliability
If the inverter is designed with larger vibration-resistant components, then the inverter can withstand engine vibrations, but the overall system size increases
Solution Approach 1:
The vibration absorption function is extracted from the inverter structure and transferred to the wiring harness itself. By routing the harness in a curved path along the outer periphery, the harness becomes the vibration-dampening element, allowing the inverter to maintain a compact size without requiring oversized vibration-resistant components.
Solution Approach 2:
The wiring harness serves as an intermediary vibration-absorbing element that protects the inverter without requiring the inverter itself to be enlarged. This mediator approach allows standard-sized inverters to be used while still providing vibration protection through the harness routing configuration.
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 design effectively suppresses vibration transmission to the inverter, allowing for a reduction in the size of the inverter components and a more compact hybrid system while maintaining efficient power transmission.
Implementation Method 1
at least a portion of the wiring harness extends between the generator housing and the inverter housing
Data Source
AI summary
A generator of a hybrid electric vehicle is electrically connected with an inverter by a harness. A generator opening is opened on a generator housing, and an inverter opening is opened on an inverter housing. The harness extends between the generator opening and the inverter opening. The harness is led out from the inverter opening in a first direction toward the generator. The harness is led out from the generator opening in a second direction that is different from the first direction. The inverter opening is set off with respect to the generator opening in the second direction, and at least a portion of the harness extends between the generator housing and the inverter housing. The harness necessarily flexes, and thereby deters transmission of vibrations from the generator to the inverter.