BEV Motor Power Cable Support Geometry for Swing Fatigue Control
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Solution Overview
Problem
In battery electric vehicles, the swinging of the power cable connecting the motor and the inverter relative to the chassis causes fatigue degradation due to excessive movement, which is not addressed in existing technologies.
Innovation Solution
The power cable is supported by a support bracket positioned closer to the center of the circular arc than half the radius, dividing its swinging into two components, and is fixed to the chassis at one end, with orthogonal bending to reduce amplitude and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the motor is supported by the suspension together with the axle, then the motor can move with the axle suspension, but the power cable swings excessively causing fatigue degradation
Solution Approach 1:
The power cable path is segmented into multiple sections by introducing support brackets at strategic positions. The cable is divided into segments between the inverter, support brackets, and motor, with each segment having controlled movement characteristics. This segmentation reduces the swinging amplitude of individual cable portions while maintaining overall motor suspension functionality.
Solution Approach 2:
Support brackets are introduced as intermediary elements between the inverter and motor to hold the power cable. These brackets are positioned closer to the center of the circular arc than half the radius, creating intermediate support points that reduce cable swing amplitude without interfering with motor suspension movement.
2Reliability
If the power cable is fixed rigidly to restrain swinging, then cable fatigue is reduced, but motor suspension movement is restricted
Solution Approach 1:
The support brackets are designed to swing together with the motor, creating a dynamic support system rather than a rigid fixed structure. This allows the brackets to move with the motor suspension while still providing effective cable support, maintaining both cable durability and suspension adaptability.
Solution Approach 2:
The support brackets combine multiple functions: they support the power cable, swing together with the motor, and are positioned to reduce cable swing amplitude. This merging of functions achieves both cable protection and suspension movement without requiring separate rigid fixing mechanisms.
3Reliability
If the support bracket is positioned closer to the center of the circular arc, then the power cable swinging amplitude is reduced, but the bracket structure becomes more complex
Solution Approach 1:
The support brackets are positioned at specific locations closer to the center of the circular arc than half the radius, creating localized support zones where cable swing amplitude is most effectively reduced. This local quality approach targets the critical swing reduction zone without requiring complex overall reconfiguration.
Data Source
AI summary
A battery electric vehicle including an axle, a motor, a suspension, an inverter, a power cable, and a support bracket is provided. The axle extends in a vehicle-width direction. The motor is coupled to the axle, and drives the axle. The suspension supports the axle and the motor, and causes the axle and the motor to swing along a circular arc when viewed in the vehicle-width direction. The inverter is fixed to a chassis, and supplies electric power to the motor. The power cable connects the inverter and the motor. The support bracket supports the power cable, and swings together with the motor. The power cable is supported by the support bracket, at a position that is closer to the center of the circular arc than a position of half of the radius of the circular arc is when viewed in the vehicle-width direction.