Power Control Unit Connection Conductor Access
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Solution Overview
Problem
The existing power control unit configuration interferes with nearby components during attachment and detachment of the connection conductor, and visual confirmation of the fastening member position is difficult due to its placement below the unit, degrading workability and maintainability.
Innovation Solution
The power control unit design includes a connection conductor that passes through a support block and is connected via a fastening member with an opening section in the upper case's inclination wall, allowing easy access and visual inspection, and an insulating cover member reduces gaps to prevent tool drop, while routing high voltage cables to avoid obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the connection conductor is disposed in the lower case with the fastening member positioned below the power control unit, then the structure is compact, but the workability for attachment and detachment is degraded due to tool interference with nearby components
Solution Approach 1:
The patent moves the opening section from the lower case (below the power control unit) to the upper case (above the power control unit), changing the spatial dimension of access. This allows the tool to approach the fastening member from above rather than from below, avoiding interference with nearby components on the motor unit side while maintaining structural compactness.
Solution Approach 2:
Instead of providing access to the fastening member from below through the lower case, the patent inverts the approach by providing access from above through the upper case. This inversion of the access direction resolves the interference problem with nearby components while maintaining the same functional outcome.
2Device complexity
If the fastening member is positioned below the power control unit, then the structure is simplified, but direct visual confirmation for maintenance becomes difficult
Solution Approach 1:
The patent changes the vertical dimension of the opening section from below the power control unit to above the power control unit. This positional change in the vertical dimension enables direct visual confirmation of the fastening member and connecting fixing section from above, while maintaining structural simplicity.
3Ease of operation
If the opening section is provided in the lower case, then access to the fastening member is provided, but tool interference with nearby components occurs during operation
Solution Approach 1:
The patent extracts the opening section from the lower case and relocates it to the upper case. This separation removes the source of tool interference from the problematic area near the motor unit components, while preserving the essential function of providing access to the fastening member.
Solution Approach 2:
By relocating the opening section from the lower case to the upper case, the patent changes the spatial dimension of tool access. This dimensional change allows the tool to operate in a different spatial zone that does not interfere with nearby components on the motor unit side.
Data Source
AI summary
A power control unit includes a power module, a support block configured to support the power module, an upper case configured to cover the power module from above, and a connection conductor configured to connect an internal power feeding passage on the side of the power module and an external power feeding passage on the side of the motor unit, wherein the connection conductor vertically passes through the support block and includes a connecting fixing section that protrudes upward than the support block and that is connected to the internal power feeding passage by a fastening member, an inclination wall inclined downward toward a side end portion of the upper wall of the upper case is provided on the upper wall of the upper case, and an opening section facing the connecting fixing section of the connection conductor is provided in the inclination wall.