On-Vehicle Power Control Unit Bracket Shock Absorption
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Solution Overview
Problem
The existing on-vehicle structure for power control units, where the unit is supported above the motor housing, faces shock absorption issues during collisions, particularly in frontal and oblique collisions, as the front bracket can deform and collapse, leading to direct contact with the housing, which may exacerbate the shock received by the power control unit.
Innovation Solution
The proposed on-vehicle structure incorporates a front bracket with a base section fixed to the housing and a support section that extends to the power control unit, featuring a geometric relationship where the support section contacts the housing before the power control unit's lower surface does, thereby alleviating the shock by weakening the momentum of the power control unit's approach to the housing. This is achieved by ensuring the support section collapses rearward and contacts the housing before the power control unit does, using a projection on either the housing or the support section to satisfy the condition G > T · (sin(B) – sin(A)), where G is the gap between the power control unit and the housing, T is the length from the coupling point to the front end, and angles A and B are defined by specific linear lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power control unit is fixed above the housing with a front bracket and rear bracket, then the power control unit is protected from vibrations and positioned for short power cables, but during collision the front bracket deforms and collapses causing the power control unit to severely contact the housing
Solution Approach 1:
The patent introduces a cushioning member (elastic element) between the power control unit and the housing. This cushioning member is pre-installed to absorb collision shocks before they reach the power control unit. When collision occurs, the elastic element deforms to absorb impact energy, preventing the power control unit from severely contacting the housing and reducing collision damage.
Solution Approach 2:
The patent introduces a cushioning member as an intermediary element between the power control unit and the housing. This intermediary component absorbs and attenuates collision forces, acting as a mediator that protects the power control unit from direct impact with the housing during frontal or oblique collisions.
2Loss of energy
If the power control unit is arranged near the motor, then power transmission loss is suppressed, but collision safety is compromised as the unit receives significant shock during frontal or overlap collisions
Solution Approach 1:
The cushioning member is pre-installed in the mounting structure to provide shock absorption capability before collision occurs. The elastic element is positioned to absorb impact forces during frontal or overlap collisions, protecting the power control unit from significant collision loads while maintaining its near-motor positioning for efficient power transmission.
3Strength
If the front bracket support section is made rigid to support the power control unit, then the power control unit is securely mounted, but during collision the rigid bracket transmits full impact force to the power control unit
Solution Approach 1:
The patent changes the mechanical parameter of the mounting bracket by introducing an elastic element with specific elasticity. This transforms the rigid bracket into a semi-rigid structure that maintains sufficient strength for secure mounting while capable of deforming to absorb collision energy, thereby reducing impact force transmission to the power control unit.
Solution Approach 2:
The mounting structure becomes a composite system combining rigid bracket components with elastic cushioning material. This composite structure leverages the strength of rigid materials for mounting support while utilizing the shock-absorbing properties of elastic materials to mitigate collision impacts on the power control unit.
Data Source
AI summary
An on-vehicle structure includes a housing of a motor and a power control unit. The power control unit is fixed by a front bracket and a rear bracket above the housing. A space is defined between a lower surface of the power control unit and the housing. The front bracket includes a base section and a support section. The support section is configured to contact with the housing before the lower surface of the power control unit contacts with an upper surface of the housing when the support section is collapsed rearward by a load applied to the power control unit from front.