Vehicle PCU Mounting Layout for Frontal Collision Protection
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Solution Overview
Problem
In hybrid vehicles with longitudinal engines, the power control unit (PCU) mounting structure faces challenges during frontal collisions, as the high-voltage cable can be ruptured and the PCU may obstruct the engine's rearward movement due to lack of space, leading to inadequate protection and potential damage.
Innovation Solution
The proposed mounting structure positions the PCU above the longitudinal engine, with an intake manifold and toeboard cross member configuration that overlaps in the fore-and-aft direction, creating space behind the PCU and shifting components to prevent direct collision loads and reduce high-voltage cable path length, thus protecting the PCU and allowing engine movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the PCU is disposed above the longitudinal engine in the engine room, then the space utilization is improved, but the high-voltage cable can be ruptured and the PCU may obstruct the engine's rearward movement during frontal collision
Solution Approach 1:
The patent positions the PCU above the engine in the vertical dimension rather than beside it in the horizontal plane,充分利用 the vertical space above the engine to create a compact layout that improves space utilization while maintaining collision protection through proper structural design
Solution Approach 2:
The patent introduces a protective structure (casing with mounting brackets) as an intermediary between the PCU and the external collision environment, absorbing and distributing collision forces to protect the high-voltage cable and PCU from direct impact
2Volume of moving object
If the intake manifold and toeboard cross member are configured to overlap in the fore-and-aft direction, then space behind the PCU is created, but the layout complexity increases
Solution Approach 1:
The intake manifold is designed to extend in the fore-and-aft direction and overlap with the toeboard cross member in the vertical projection, utilizing three-dimensional spatial arrangement to create space behind the PCU without increasing horizontal footprint
Solution Approach 2:
The intake manifold and toeboard cross member are arranged to nest within each other's spatial envelope in the fore-and-aft direction, with the intake manifold positioned above and overlapping the toeboard cross member, efficiently creating rear space while minimizing layout complexity
Data Source
AI summary
A power control unit mounting structure mounted on a vehicle includes an engine in an engine room at a front of the vehicle, an intake manifold disposed above the engine, a power control unit that is disposed above the engine, coupled to a cable, and controls power of a drive motor, and a toeboard cross member disposed on a toeboard. The engine and the toeboard cross member partly overlap in a projected plane along a fore-and-aft direction to provide a space behind the control unit in a front view of the vehicle. The intake manifold and the control unit are disposed within a contour of the engine in a plan view of the vehicle. The intake manifold is disposed ahead of the control unit, and portions of intake pipes of the intake manifold on both sides extend rearward and are partly opposed to both side surfaces of the control unit.