Hybrid Vehicle Harness Layout for Inverter 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 the rigid and short wiring harnesses, leading to increased size and vibration resistance requirements for the inverter components.
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 lead-out directions from the generator and inverter housings, allowing the harness to flex and absorb vibrations, thereby reducing transmission to the inverter and enabling a more compact system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the wiring harness is routed straight and kept short to reduce space, then the wiring structure is simplified, 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 instead of a straight line, creating a U-shaped configuration that allows the harness to flex and absorb vibrations from the internal combustion engine, preventing vibration transmission to the inverter while maintaining compact space utilization
Solution Approach 2:
The routing direction parameters of the wiring harness are changed at both the generator housing and inverter housing openings, creating angular deviations that form a curved path. This changes the physical state of the wiring harness from rigid-straight to flexible-curved, enabling vibration absorption
2Reliability
If the wiring harness is made thick to handle high-voltage AC three-phase power, then electrical conductivity is improved, but the harness becomes rigid and transmits vibrations more effectively
Solution Approach 1:
The curved routing configuration introduces flexibility into the thick wiring harness through geometric design rather than material thinning. The U-shaped path creates natural flex points that allow the harness to absorb vibrations while maintaining its thick construction for high-voltage electrical conductivity
3Reliability
If the inverter is designed with vibration-resistant components to handle transmitted vibrations, then reliability under vibration is improved, but the size of the inverter increases
Solution Approach 1:
The vibration absorption function is extracted from the inverter components and transferred to the wiring harness itself. By routing the harness in a curved path, the harness becomes the vibration isolation element, allowing the inverter to use smaller, less robust components
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 from the internal combustion engine to the inverter, reducing the need for excessive vibration resistance in inverter components and allowing for a downsized hybrid system unit.
Implementation Method 1
the wiring harness, which is short and, in patent literature 1, routed straight, does not flex, so that it transmits the vibrations to the inverter
Data Source
Figure 1
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Figure 3
AI summary
A generator (3) of a hybrid electric vehicle (1) is electrically connected with an inverter (5) by a harness (9). A generator opening (3O) is opened in a generator housing (3H), and an inverter opening (50) is opened in an inverter housing (5H). The harness (9) extends between the generator opening (3O) and the inverter opening (5O). The harness (9) is led out from the inverter opening (5O) in a first direction (D1) toward the generator (3). The harness (9) is led out from the generator opening (3O) in a second direction (D2) that is different from the first direction (D1). The inverter opening (5O) is offset with respect to the generator opening (3O) in the second direction (D2), and at least a portion of the harness (9) extends between the generator housing (3H) and the inverter housing (5H). The harness (9) necessarily flexes, and thereby deters transmission of vibrations from the generator (3) to the inverter (5).