High-Voltage Cable Routing With Sheath Wear Detection
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Solution Overview
Problem
Existing fire fighting vehicles with internal combustion engines face challenges in efficiently transitioning to electrified systems without requiring operators to learn new control interfaces and vehicle layouts, and there is a need for reliable detection of high voltage cable damage or wear.
Innovation Solution
A high voltage system for electrified vehicles incorporating a high voltage cable with detection layers to identify damage or wear, integrated into a driveline that maintains the appearance and operation of traditional vehicles, and includes a control system to manage various modes of operation, including dual drive and hybrid configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If detection layers are added to the high voltage cable, then the reliability of damage detection is improved, but the device complexity increases
Solution Approach 1:
The detection layer is nested within the cable structure, specifically positioned between the conductor and the outer sheath. This nested configuration allows the detection functionality to be integrated into the existing cable without adding external components, thereby improving damage detection reliability while minimizing increases in device complexity.
Solution Approach 2:
The cable employs a composite structure combining traditional cable materials (conductor, insulation, sheath) with a specialized detection layer containing conductive particles or fibers. This composite approach enables damage detection capability while maintaining the overall cable structure and using materials that integrate seamlessly with existing cable construction.
2Productivity
If electrified systems are integrated into existing fire fighting vehicles, then the productivity is improved, but the ease of operation deteriorates due to new control interfaces
Solution Approach 1:
The control system is designed with multi-functionality, allowing it to operate in multiple modes (traditional internal combustion engine mode and electrified mode) through a single unified interface. This universal control approach enables the vehicle to leverage electrified systems for improved productivity while maintaining familiar control patterns that preserve ease of operation for operators.
Solution Approach 2:
The control interface dynamically adapts its behavior based on the selected operating mode. When in electrified mode, the interface presents controls appropriate for electric powertrain operation, while automatically reverting to traditional controls when in internal combustion mode. This dynamic adaptation allows operators to work with familiar interfaces regardless of the power source being used, maintaining ease of operation while enabling productivity improvements from electrification.
Data Source
AI summary
A high voltage system for an electrified vehicle includes a first high voltage component, a second high voltage component, and a high voltage cable. The high voltage cable provides power between a first location of the first high voltage component and a second location of the second high voltage component. The high voltage cable includes a core, a sheath disposed around and along the core, and one or more detection layers at least one of (a) disposed around and along the sheath or (b) disposed within the sheath. The one or more detection layers are configured to facilitate detecting at least one of (a) damage or wear to the sheath or (b) a location of the damage or wear along the sheath.