Vehicle Power Control Device Rib Impact Protection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In electric vehicles, the power control device mounted above the housing via a bracket can deform upon collision, causing the device to move downward and potentially damage the cable connection portion due to exposed bolt heads interfering with the cable connection on the housing.

Innovation Solution

A rib is provided on the lower portion of the power control device's casing, protruding below the bolt head, to prevent contact between the bolt head and the cable connection portion during a collision, ensuring the rib absorbs the impact instead.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the power control device is mounted above the housing via a bracket with exposed bolt heads, then the device can be securely fixed and easily assembled, but the bolt heads may interfere with the cable connection portion during collision, causing damage

Engineering Contradiction:

Improveease of assemblyVSAvoiddamage to cable connection portion

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

A rubber sheet is introduced as an intermediary protective layer between the bolt head and the cable connection portion. The rubber sheet is positioned on the housing to cover the cable connection portion, preventing direct contact between the bolt head and the cable during collision. This intermediary element absorbs the impact and protects the vulnerable cable connection area while maintaining the original mounting structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the power control device is positioned close to the housing for compact design, then space efficiency is improved, but the device may contact the housing during collision, causing damage

Engineering Contradiction:

Improvemounting spaceVSAvoidcontact damage during collision

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The rubber sheet serves as a protective intermediary that allows the power control device to be mounted closer to the housing without risking damage. The rubber material absorbs impact forces during collision, preventing direct contact damage between the device and housing while maintaining the compact mounting arrangement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The rubber sheet is pre-installed on the housing at the cable connection portion before the power control device is mounted. This beforehand cushioning creates a protective barrier that anticipates potential collision damage, allowing the device to be positioned in a compact arrangement close to the housing while being protected from impact forces.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS10259339B1Structure of mounting power control device in vehicle

Publication Date: 2019.04.16 TOYOTA JIDOSHA KK

AI summary

A structure of mounting a power control device in a vehicle includes a housing that houses an electric motor for running, a power control device fixed above the housing with a gap between the power control device and the housing, and a cable connection portion provided on an upper surface of the housing at a position facing the power control device. A head of a bolt may be exposed on a lower portion of a casing of the power control device at a position facing the cable connection portion and a rib may be provided on the lower portion of the casing next to the head of the bolt, the rib protruding lower than the head of the bolt.