Inverter Bracket System for Electric Vehicle Crash Protection
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Solution Overview
Problem
Existing electric vehicle designs face challenges in protecting the power cable connecting the inverter and motor from breakage during crashes, as previous solutions either lack design flexibility or increase the risk of cable damage due to differential deformation of vehicle components.
Innovation Solution
The use of a front and rear bracket system to fix the inverter on top of the drive train with a gap between them, allowing the inverter to sink backward and absorb impact, combined with a wavy front bracket to enhance impact absorption and reduce cable breakage risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the inverter is fixed directly to the motor to shorten the power cable, then the cable length is reduced, but the risk of cable breakage during crash increases due to impact forces
Solution Approach 1:
A cushioning member is provided between the inverter and the motor to absorb impact forces during crash before they reach the power cable. This beforehand cushioning prevents the cable from breaking while maintaining the compact arrangement that keeps the cable short.
Solution Approach 2:
The cushioning member acts as an intermediary element between the inverter and motor, mediating the impact forces that occur during crash. This intermediary structure protects the power cable from direct transmission of impact forces while allowing the inverter to move relative to the motor.
2Length of moving object
If the inverter is fixed to the motor housing, then the power cable can be kept short, but design flexibility is reduced due to fixed positioning requirements
Solution Approach 1:
The inverter is allowed to move relative to the motor through the cushioning member, creating a dynamic positioning system. This enables the inverter to be positioned optimally for cable length while maintaining the ability to absorb impact, thereby preserving design flexibility.
Solution Approach 2:
The cushioning member allows for changes in the distance and relative position between the inverter and motor. This parameter flexibility enables optimization of cable length while accommodating different crash scenarios and design requirements.
3Stability of the object's composition
If rigid fixing structures are used to secure the inverter and motor, then positional stability is improved, but impact absorption capability is reduced
Solution Approach 1:
The cushioning member functions as a flexible element between the rigid inverter and motor housings. This flexible component maintains positional stability during normal operation while absorbing impact forces during crash, preventing rigid force transmission that would damage the power cable.
Solution Approach 2:
The cushioning member is positioned beforehand between the inverter and motor to provide impact absorption. This pre-positioned cushioning structure allows rigid fixing for stability while preparing the system to absorb impact forces before they reach the power cable.
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 configuration effectively reduces the likelihood of power cable breakage during crashes by allowing the inverter to move closer to the drive train, absorbing impact and maintaining cable integrity, while also improving design flexibility and reducing the risk of bracket failure.
Implementation Method 1
the front bracket has a wavy shape between a fixing point on a drive train side and a fixing point on an inverter side as seen along a lateral direction of the vehicle. The wavy shape of the front bracket makes a movable distance of a forward part of the inverter be longer at the time of receiving impact from the front.
Data Source
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AI summary
This specification provides a structure in which a power cable connecting an inverter with a motor arranged in the front compartment is protected from breakage upon a crash. A hybrid vehicle 100 includes an inverter 5 fixed to a top of a drive train 2 with a gap by front and rear brackets 12, 13. The front bracket 12 connects a front surface of the inverter 5 with the drive train 2 and the rear bracket 13 connects a rear surface of the inverter 5 with the drive train 2. The front surface of the inverter 5 corresponds to a frontward side surface of the vehicle. When the vehicle crashes, the front and rear brackets 12, 13 cause the inverter 5 move backward and downward so that a distance between the inverter 5 and the drive train 2 is reduced. Therefore, a power cable 22 is protected from breakage.