High-Voltage Cable Connector Layout to Limit Cabin EMI
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Solution Overview
Problem
The existing connection structures between high-voltage cables and control units in electric vehicles allow electromagnetic waves to propagate into the passenger compartment, complicating and costing more to mitigate this issue, and require a service plug near the compartment for maintenance, which is not safe.
Innovation Solution
A high-voltage cable connection structure that uses a connector with insulating bushings and tubes to disconnect high-voltage cables from the control unit outside the passenger compartment, eliminating the need for a service plug and reducing electromagnetic interference with a simple configuration, and includes an interlock device to ensure safe maintenance by shutting off the high-voltage circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the service plug is disposed near the passenger compartment for maintenance access, then maintenance of the high-voltage circuit can be performed, but electromagnetic waves propagate into the passenger compartment requiring additional shielding parts
Solution Approach 1:
The high-voltage control unit is extracted from the passenger compartment and relocated to the engine compartment, separating the high-voltage equipment from the passenger space. This eliminates the need for service plugs near the passenger compartment while preventing electromagnetic wave propagation into the passenger area, as the entire control unit is positioned outside the affected zone.
2Object-affected harmful factors
If additional parts are added to reduce electromagnetic wave propagation into the passenger compartment, then electromagnetic interference is mitigated, but the structure becomes more complex and costly
Solution Approach 1:
Instead of adding shielding parts or filters to the existing connector structure, the solution extracts the entire high-voltage control unit from the passenger compartment and relocates it to the engine compartment. This eliminates the need for additional electromagnetic shielding components, maintaining structural simplicity while effectively preventing electromagnetic wave propagation into the passenger area.
3Object-affected harmful factors
If the service plug is removed from the passenger compartment to reduce electromagnetic interference, then electromagnetic wave propagation is reduced, but maintenance access becomes more difficult
Solution Approach 1:
The high-voltage control unit is extracted from the passenger compartment and relocated to the engine compartment, where maintenance can be performed on the connector without requiring service plugs near the passenger area. This relocation maintains ease of maintenance access while eliminating electromagnetic wave propagation into the passenger compartment, as all high-voltage components are positioned outside the passenger space.
Data Source
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AI summary
A high-voltage cable connection structure includes a first connector (40) to which a plurality of first high-voltage cables (30), each connected to a corresponding one of a plurality of terminals of a high-voltage battery, are connected, and a connector receptacle (21) provided in a high-voltage control unit (20) disposed outside a vehicle passenger compartment. Inserting the first connector (40) into and pulling out the first connector (40) from the connector receptacle (21) allows connection and disconnection between the plurality of first high-voltage cables (30) and the high-voltage control unit (20).