Frame Rail HV Cable Layout for Electrified Fire Truck Chassis
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Solution Overview
Problem
Firefighting vehicles with internal combustion engines face challenges in efficiency, environmental impact, and operational complexity, particularly in transitioning to electrified systems without compromising performance or requiring significant retraining for operators.
Innovation Solution
The development of an electrified firefighting vehicle with a hybrid driveline that integrates an electromechanical transmission system, energy storage, and a high-voltage cable routing within the chassis frame, allowing for seamless operation between electric and engine modes while maintaining the appearance and control layout of traditional vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high voltage cables are routed externally along the chassis, then installation and maintenance are easier, but safety risks and aesthetic appearance deteriorate
Solution Approach 1:
The high voltage cable is nested within the frame rail structure, specifically routed through the interior channel of the frame rail. This nesting approach allows the cable to be protected within the existing structural framework while maintaining accessibility for installation and maintenance, thus improving safety without significantly compromising ease of manufacture
Solution Approach 2:
The frame rail acts as an intermediary structure that houses and protects the high voltage cable. By using the frame rail as a mediator between the cable and the external environment, the cable gains protection from physical damage and environmental factors, reducing safety risks while the frame rail's structural design maintains accessibility
2Object-affected harmful factors
If high voltage cables are routed through the frame rail interior channel, then safety and protection improve, but installation complexity and access difficulty worsen
Solution Approach 1:
The frame rail serves multiple functions: it provides structural support for the chassis, aesthetic coverage, and a protected routing path for the high voltage cable. By making the frame rail multi-functional, the cable routing leverages the existing structure rather than requiring separate protective conduits, thus improving protection without significantly increasing routing complexity
Solution Approach 2:
The frame rail is designed with an interior channel specifically prepared for cable routing during the chassis manufacturing process. This preliminary preparation of the routing path simplifies subsequent cable installation, as the channel is already formed and integrated into the frame rail structure before cable installation occurs
3Object-generated harmful factors
If the vehicle is converted to electric powertrain, then environmental impact and efficiency improve, but operator training requirements and operational complexity worsen
Solution Approach 1:
The electrified fire fighting vehicle replicates the operational characteristics, control interfaces, and response procedures of traditional internal combustion engine vehicles. By copying the familiar operational patterns, the vehicle maintains ease of operation for firefighters while achieving improved environmental performance through electric powertrain technology
Solution Approach 2:
The vehicle system is designed to be self-explanatory and self-regulating, with automated functions and intuitive controls that reduce the need for extensive operator training. The system manages its own operations through integrated control systems that adapt to operational conditions, thereby simplifying the operator's role while maintaining effectiveness
4Adaptability or versatility
If high voltage components are distributed along the longitudinal length, then power management flexibility improves, but cable routing complexity and installation difficulty worsen
Solution Approach 1:
The cable routing utilizes the vertical and depth dimensions within the frame rail structure rather than only horizontal routing along the vehicle length. By routing cables through the interior channel of the frame rail in three-dimensional space, the system accommodates distributed high voltage components along the longitudinal length while managing cable complexity through spatial optimization
Data Source
AI summary
An electrified fire fighting vehicle includes a chassis, at least one of a water pump, a water tank, or an aerial ladder supported by the chassis, a first high voltage component, a second high voltage component, and a high voltage cable. The chassis includes a first frame rail and a second frame rail. The chassis defines a longitudinal length of the electrified fire fighting vehicle. The first high voltage component is positioned at a first location along the longitudinal length. The second high voltage component is positioned at a second location along the longitudinal length. The high voltage cable provides power between the first location and the second location. At least a portion of the high voltage cable is received within the first frame rail such that the portion of the high voltage cable is routed along and through an interior channel of the first frame rail.