Vehicle Power Controller Mounting Structure with Asymmetric Protrusions
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Solution Overview
Problem
In vehicles, the power controller mounted in the front compartment may be thrust back during a collision, causing the connector attached to its back portion to interfere with the cowl panel, potentially leading to damage and preventing the discharge of a capacitor, which is crucial for safety.
Innovation Solution
A mounting structure with protrusions on the housing of the power controller, where the pair of protrusions on the lateral sides are positioned such that the one closer to the center line contacts the cowl panel earlier than the other, distributing the load and preventing excessive stress on either protrusion, thus protecting the connector from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is attached to the back portion of the housing of the power controller, then the layout of the power controller can be optimized, but the connector may interfere with the cowl panel during collision and be damaged
Solution Approach 1:
The protrusions serve as intermediary elements between the connector and the cowl panel. During collision, the protrusions make contact with the cowl panel first, acting as a mediator that prevents direct contact between the connector and the panel, thereby protecting the connector from damage while maintaining the optimized layout
Solution Approach 2:
The protrusions are positioned ahead of the connector in the collision direction, providing beforehand cushioning by absorbing the initial impact force during collision. This prior cushioning prevents the full impact force from reaching the connector, protecting it from damage
2Device complexity
If the protrusions are positioned symmetrically, then the structure is simple, but excessive stress may be concentrated on either protrusion during collision
Solution Approach 1:
The protrusions are arranged asymmetrically relative to the centerline of the power controller. The first protrusion is positioned closer to the centerline than the second protrusion, creating an asymmetric configuration that optimizes load distribution during collision by leveraging the structural characteristics of the cowl panel
3Productivity
If the power controller is mounted in the front compartment, then it can be positioned close to the traction motor, but the connector may be damaged during collision
Solution Approach 1:
The protrusions act as intermediary protective elements that intervene between the connector and the cowl panel during collision. They make contact with the cowl panel first, preventing direct impact on the connector and protecting it from collision damage while maintaining the front compartment mounting position
Data Source
AI summary
A structure of mounting a power controller in a vehicle, the power controller to be mounted in a front compartment of the vehicle: includes a connector attached to a back portion of a housing of the power controller; a cowl panel positioned behind the connector; and a pair of protrusions provided on the housing. Each of the pair of protrusions is arranged on a corresponding lateral side of the connector. Back ends of the protrusions are positioned on a back side with respect to a back end of the connector. A distance from the back end of one protrusion of the pair of protrusions to the cowl panel is shorter than a distance from the back end of the other protrusion to the cowl panel, the one protrusion being closer to a center line in a width direction of the vehicle than the other protrusion is.