Fuel Cell Power Distributor Cable Bumper for Collision Protection
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Solution Overview
Problem
High-voltage cables in fuel cell vehicles pose a risk of combustion, explosion, or electric shock during collisions due to potential contact with the dash panel, necessitating protection measures.
Innovation Solution
A fuel cell vehicle design incorporating a cable bumper coupled to the power distributor to surround and protect voltage cables, featuring shock-absorbing and shock-dispersing members, and a specific housing configuration to prevent damage and ensure safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If voltage cables are directly connected to the power distributor without protection, then the device complexity is reduced, but the reliability deteriorates due to collision risks
Solution Approach 1:
The cable bumper is designed to provide shock absorption and protection to the voltage cables before collision damage can occur. The bumper includes shock-absorbing members that are pre-configured to deform or absorb impact energy during collisions, preventing direct damage to the cables and connectors.
Solution Approach 2:
The cable bumper acts as an intermediary protective structure between the voltage cables and the external collision environment. It includes protective housings and shock-absorbing members that mediate the impact forces, preventing direct contact between collision forces and the electrical components.
2Reliability
If a cable bumper with shock-absorbing members is added to protect voltage cables, then the reliability improves, but the device complexity increases
Solution Approach 1:
The cable bumper is segmented into multiple functional components including protective housings, shock-absorbing members, and mounting structures. This segmentation allows each component to be optimized for its specific function while enabling modular assembly and easier manufacturing.
Solution Approach 2:
The bumper structure utilizes composite construction combining rigid protective housings with flexible shock-absorbing members. This composite approach provides both structural integrity for protection and energy absorption capability, achieving high reliability without excessive weight or complexity.
3Strength
If the cable bumper is made with high rigidity to protect cables, then the strength improves, but the shock-absorbing capability deteriorates
Solution Approach 1:
Different parts of the bumper structure have different rigidity characteristics optimized for their specific functions. The protective housings have high rigidity for strength and protection, while the shock-absorbing members have lower rigidity for energy absorption. This local differentiation of mechanical properties resolves the contradiction between strength and shock absorption.
Solution Approach 2:
The bumper employs composite construction combining rigid materials for protective housings with flexible materials for shock-absorbing members. This allows the structure to simultaneously provide high strength for cable protection and adequate shock-absorbing capability for collision mitigation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces the risk of electrical shock and combustion by absorbing and dispersing impact forces, ensuring occupant safety and compliance with high-voltage safety regulations.
Implementation Method 1
the cable bumper may include a shock-absorbing member
Implementation Method 2
dispersing impact forces
Data Source
AI summary
An embodiment fuel cell vehicle includes a fuel cell, a power distributor disposed on the fuel cell and configured to receive power generated by the fuel cell, a voltage cable connected to a rear side of the power distributor, and a cable bumper coupled to the rear side of the power distributor and surrounding a portion of the voltage cable.