Impact Device Safety Arrangement for Electric Commercial Vehicles
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Solution Overview
Problem
Existing safety systems in battery electric commercial vehicles are inadequate in protecting drivers and passengers from high voltage hazards during collisions, as they may not detect all critical situations, including low-speed collisions or angled impacts, and can lead to unwanted system shutdowns during emergency braking.
Innovation Solution
A safety system comprising an impact device that forms a mechanical connection between the chassis and a vehicle unit, allowing relative displacement during collisions to absorb energy and interrupt the control circuit, thereby switching off the high voltage system, without the need for additional crash sensors, using an electrical conductor that disconnects to trigger the shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crash sensors are used to trigger switching off the high voltage system, then the system can detect collisions, but the system may switch off in unwanted situations such as emergency braking or may not detect low-speed collisions
Solution Approach 1:
The patent replaces the electronic crash sensor system with a passive mechanical disconnect mechanism. The electrical conductor is mechanically connected to the impact device, and when the impact device moves relative to the chassis during a collision, the conductor is pulled out or disconnected, automatically interrupting the control circuit. This mechanical substitution eliminates the need for complex sensor electronics, thresholds, and control logic while providing reliable detection of actual collision events.
Solution Approach 2:
The safety system uses the collision force itself to trigger the shutdown by allowing the impact device to move and mechanically disconnect the conductor. The system serves itself by using the kinetic energy from the collision to perform the safety function, without requiring external power, sensors, or active control systems. The relative movement between the impact device and chassis during impact automatically pulls the conductor out, creating a passive self-activating safety mechanism.
2Reliability
If the control circuit is interrupted by relative movement between chassis and unit, then the high voltage system switches off immediately, but the impact device must allow relative displacement which may seem counterintuitive for safety
Solution Approach 1:
The patent segments the mechanical connection into two functional parts: the impact device that absorbs energy through controlled movement, and the electrical conductor that maintains connection during normal operation but disconnects during collision. This segmentation allows the system to simultaneously achieve strong mechanical coupling for normal use and automatic electrical disconnection for safety, by separating the structural function from the electrical function.
Solution Approach 2:
The mechanical connection is designed to be dynamic rather than rigid. The impact device is allowed to move relative to the chassis during a collision, and this dynamic movement is what triggers the conductor disconnection. The system transitions from a static strong connection to a dynamic one that can adapt its state based on operating conditions, providing both strength during normal operation and automatic shutdown during impact.
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 solution provides a robust and simple safety measure that effectively reduces the risk of electrical hazards by immediately switching off the high voltage system during collisions, protecting drivers and passengers from electrocution and potential fires, while avoiding unnecessary shutdowns during normal driving conditions.
Implementation Method 1
The impact device is arranged for allowing a relative displacement between the unit and the chassis, to protect the unit by absorbing collision energy
Implementation Method 2
The impact device comprises an electrical conductor arranged for disconnecting by the relative movement between the chassis and the unit. When disconnected, the control circuit is interrupted, thereby switching the electric power module from the active state to the passive safe state
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
A commercial vehicle, comprising an electric power module, a high voltage system, a control circuit, and an impact device arranged to protect a unit of the vehicle in case of a collision, by absorbing collision energy. The control circuit at least partially passes through the impact device. The impact device comprises an electrical conductor arranged for disconnecting by a relative movement between the chassis and the unit. When disconnected, the control circuit is interrupted, thereby switching the electric power module from an active state, in which electric power is provided to the high voltage system, to a passive safe state, in which electric power to the high voltage system is switched off.