Power Control Device Disengagement Mechanism for Collision Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicular instrument-mounting structures face challenges in protecting power control devices from collision impacts, particularly when auxiliary batteries are positioned near the power control devices, leading to potential circuit breakage due to reactive forces, which can be costly and space-constrained to address through increased casing rigidity or disengagement mechanisms.
Innovation Solution
A vehicular instrument-mounting structure featuring a guide member and linkage mechanism that disengages the power control device from the motor case upon impact, allowing the auxiliary battery to push the power control device rearward, with the auxiliary battery positioned forward of the power control device and mounted on a vehicular skeleton member to absorb impact, enabling efficient high-voltage discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the auxiliary battery is disposed near the power control device to maximize space utilization, then space efficiency is improved, but the risk of circuit breakage due to collision impact increases
Solution Approach 1:
The power control device is divided into a main body and a movable relay box section. The relay box can be separated from the main body during collision, isolating the high-voltage circuit from impact forces generated when the auxiliary battery is pushed by external objects.
Solution Approach 2:
A guide surface is introduced as an intermediary mechanism between the auxiliary battery and the relay box. The guide surface controls the movement path of the relay box during collision, ensuring smooth backward movement while preventing direct impact transmission to the high-voltage circuit.
2Reliability
If the power control device is protected from collision impact, then circuit reliability is improved, but device complexity increases due to disengagement mechanisms
Solution Approach 1:
The relay box containing the high-voltage circuit is extracted as a separate movable component from the main power control device body. This allows the relay box to be independently positioned and disengaged during collision, protecting the high-voltage circuit without requiring complex protection mechanisms in the main body.
Solution Approach 2:
The relay box utilizes the collision force itself to trigger its own protective movement. When the auxiliary battery is pushed by external objects, the resulting force automatically moves the relay box backward along the guide surface, eliminating the need for external sensors or control systems to activate the protection mechanism.
3Reliability
If the power control device is positioned toward the rear to avoid impact, then collision protection is improved, but wiring complexity and space utilization worsen
Solution Approach 1:
The relay box is designed to be movable rather than fixed, allowing it to dynamically adjust its position during collision. This dynamic capability enables the relay box to remain in an optimal position during normal operation while automatically moving to a protected position during impact, eliminating the need for permanent rearward positioning and its associated wiring complexity.
Data Source
AI summary
The present invention comprises side members (15), which are vehicular skeleton members of a hybrid vehicle (10); a front cross member (18) for connecting the two side members (15); spring supports (16) connected to the side members (15); an auxiliary battery arranged further towards the vehicle front relative to a PCU (13) and attached to the front cross member (18) via a support platform (23) and a securing piece (22); a radiator (17) attached to the front cross member (18); a motor case (12) and an engine (11) connected to the vehicular skeleton member via an engine mount; an axle (25) extending from the motor case (12); and a PCU (13) connected to the motor case (12) via a guide plate (19) and a linkage bolt. Thus, there is provided a vehicular instrument-mounting structure capable of inhibiting collision of a power control device or other vehicle-mounted instrument with another member, and inhibiting damage caused to the power control device or other vehicle-mounted instrument during a vehicle collision.