Hybrid Vehicle Power Cable Routing for Side-Collision Tension Relief
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Solution Overview
Problem
Existing power line routing structures in hybrid vehicles are inadequate in protecting power lines during a side collision, as they generate excessive tension leading to wire breakage due to the displacement of terminal blocks and the interference of the fuel tank.
Innovation Solution
A power line routing structure that includes an extra length area with slack formed along the side wall of a cross member, allowing the power line to absorb position displacement of the terminal block without generating excessive tension, and is further protected by flexible protector members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power line is routed along the side wall of the cross member to bypass the fuel tank, then the power line can be protected from direct interference by the fuel tank, but the power line generates excessive tension during side collision causing wire breakage
Solution Approach 1:
The patent applies beforehand cushioning by providing a slack portion in the power line routing. The power line is routed to include a slack portion that can absorb collision forces before they reach the wire itself. This pre-configured slack acts as a cushioning mechanism that prevents excessive tension during side collisions, resolving the contradiction between protection and tension resistance.
Solution Approach 2:
The patent changes the geometric parameter of the power line routing by introducing a slack portion with specific length and positioning. This parameter change allows the power line to have sufficient tension during normal operation while accommodating displacement during collision. The slack portion's dimensions are optimized to provide protection without causing excessive tension.
2Stability of the object's composition
If the power line is fixed to the side walls of cross members and side members to regulate position displacement, then the routing structure is stable, but large tension is generated in the power line during terminal block displacement
Solution Approach 1:
The patent segments the power line routing into multiple portions: a fixed portion attached to the side wall of the cross member and a slack portion that remains mobile. This segmentation allows the routing structure to maintain stability through the fixed portion while the slack portion absorbs displacement forces, preventing excessive tension in the entire power line.
Solution Approach 2:
The patent introduces dynamics to the routing structure by allowing the power line to transition from a fully fixed state to a state with a mobile slack portion. The slack portion can dynamically adjust its position and tension level based on operational conditions, maintaining stability during normal use while accommodating forces during collision events.
Data Source
AI summary
On a lower side of a floor (2), a battery storage section (31) is formed on a front side of a cross member (27) that connects left and right side members (3l, 3r) to dispose a driving battery (34), a tank storage section (30) is formed on a rear side to dispose a fuel tank (32) and a driving motor (9) is disposed on a rear side of the tank storage section (30). A power cable (26) from a terminal block (34a) of the driving battery (34) is routed and fixed as appropriate so as to bypass the fuel tank (32) via the left side of the fuel tank (32) in the tank storage section (30) and connected to the driving motor (9) via a junction box (21). In an extra length routing area (37) on a side wall (27a) of the cross member (27), an extra length area (26a) is formed by slackening the power cable (26) in a semicircular shape.