Inverter Controller Shelf with Deformation Trigger
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Solution Overview
Problem
The challenge of packaging an inverter system controller module (ISCM) in a hybrid electric vehicle's engine compartment, originally designed for a conventional internal combustion engine, is complicated by size and weight differences, requiring innovative support solutions that ensure safety, durability, NVH, and cost-effectiveness without additional weight or complexity.
Innovation Solution
A frame geometry featuring a transverse rail, side rails, an inclined equipment shelf, and a lateral brace supports the ISCM above the hybrid electric transmission, utilizing carried-over structural components, with a deformation trigger to absorb kinetic energy in collisions, allowing efficient use of existing vehicle platform components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the ISCM is separated from the hybrid transmission, then packaging flexibility is improved, but the challenge of supporting the independent ISCM in limited space increases
Solution Approach 1:
The support structure is divided into multiple functional segments: an equipment shelf for mounting the ISCM, a deformation trigger for crash energy absorption, and a lateral brace for structural support. This segmentation allows each component to be optimized independently for its specific function while collectively solving the packaging challenge.
Solution Approach 2:
The equipment shelf serves multiple functions: it provides a mounting surface for the ISCM, acts as a structural support element, and incorporates a deformation trigger for crash energy management. This multi-functionality reduces the need for additional separate components, addressing the space limitation in the engine compartment.
2Ease of manufacture
If carried-over structural components are used, then manufacturing cost is reduced, but the challenge of fitting the ISCM in the original engine compartment increases
Solution Approach 1:
The equipment shelf extends in multiple dimensions from the transverse rail, creating a three-dimensional support structure that utilizes vertical and lateral space efficiently. This dimensional approach allows the ISCM to be positioned above the transmission without interfering with other engine compartment components.
Solution Approach 2:
The equipment shelf acts as an intermediary structure between the existing transverse rail and the ISCM. It adapts the original structural components to accommodate the new hybrid powertrain equipment without requiring modification of the carried-over frame members.
3Reliability
If a deformation trigger is added to absorb collision energy, then safety is improved, but device complexity increases
Solution Approach 1:
The deformation trigger is merged with the equipment shelf structure, forming an integrated component rather than a separate safety device. This combination allows crash energy absorption functionality to be incorporated into the existing support structure without adding discrete parts or complex mechanisms.
Solution Approach 2:
The deformation trigger is designed to automatically activate during a crash event, absorbing kinetic energy through controlled deformation without requiring external control systems, sensors, or active mechanisms. The structure serves its own safety function through passive energy absorption.
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 effectively supports the ISCM in a compact engine compartment, absorbing collision energy and maintaining structural integrity without additional reinforcement, thus optimizing space, safety, and cost in retrofitting conventional vehicles with hybrid powertrains.
Implementation Method 1
a junction between the inclined portion and the tray comprises a deformation trigger designed to yield in the event of a forward collision event. By properly designing the deformation trigger, the equipment shelf may absorb the kinetic energy caused by rearward movement of the ISCM during a crash.
Data Source
AI summary
A hybrid-electric vehicle has an engine compartment defined by a transverse rail extending generally parallel to a lateral axis of the vehicle, first and second side rails extending forwardly from the transverse rail, and a hood extending over the engine compartment. A hybrid-electric transmission is located in the engine compartment and an inverter system controller module (ISCM) is supported on an equipment shelf extending between the hybrid electric transmission and the hood. The equipment shelf includes an inclined portion attached to the transverse rail and extending upwardly and forwardly at an oblique angle; a generally horizontal tray projecting forwardly from the inclined portion above the hybrid electric transmission; and a lateral brace extending from a forward end of the tray laterally to the first side rail. The junction between the inclined portion and the tray forms a deformation trigger that absorbs crash loads.