Electric Motorcycle Cable Harness Layout for Easier Motor Mounting
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Solution Overview
Problem
The existing straddled electric vehicles face difficulties in workability due to the restricted length of the power cable connecting the drive circuit and electric motor, which limits the sequential mounting of these components on the body frame.
Innovation Solution
A straddled electric vehicle design featuring a first cable harness with a forward-located portion and a curved configuration, allowing for a sufficient length and reduced load on the power cables, while maintaining a compact layout and preventing vehicle width increase, with the motor unit positioned behind the motor drive unit and battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drive circuit and electric motor are connected with a power cable before mounting on the body frame, then electrical connection is established, but the mounting workability is restricted due to cable length limitations
Solution Approach 1:
The cable harness is routed through the longitudinal direction of the vehicle body, utilizing the length dimension rather than only the lateral dimension. This allows the cable to reach from the drive circuit to the motor unit even when both components are mounted on opposite sides of the body frame, resolving the contradiction between establishing electrical connection and maintaining mounting workability.
2Ease of operation
If the motor unit and motor drive unit are positioned far apart to accommodate cable length, then mounting flexibility is improved, but the vehicle width increases
Solution Approach 1:
Instead of positioning components far apart in the lateral dimension to accommodate cable length, the solution routes the cable through the longitudinal dimension of the vehicle body. This allows compact lateral positioning of the motor unit and drive circuit while maintaining mounting flexibility through sufficient cable length routed along the body's length.
Solution Approach 2:
The cable harness includes a curved portion with a radius of curvature greater than three times the cable diameter, allowing the cable to bend smoothly around the battery and other components. This curved routing enables the cable to reach between components positioned close together laterally without increasing vehicle width, while maintaining mounting flexibility.
Data Source
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AI summary
To improve workability of attaching a motor drive unit and a motor unit to a vehicle body, an electric two-wheeled vehicle 1 includes a battery 50, a motor unit 40, a motor drive unit 30, and a first cable harness 61 for electrically connecting an electric motor 41 and a drive circuit 31 and sending power of the battery 50 from the drive circuit 31 to the electric motor 41. The motor unit 40 is disposed behind the motor drive unit 30. The first cable harness 61 has, in a middle thereof, a portion (margin portion 61e) located forward than a front surface 36g of the motor drive unit 30.