Power Unit Room Cable Layout for High-Voltage Collision Protection
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Solution Overview
Problem
In plug-in hybrid electric vehicles (PHEVs) and battery electric vehicles (EVs), the power unit room is crowded with many components, making it difficult to provide an empty space and posing a risk of secondary accidents like electric shock due to damage to high voltage components during collisions.
Innovation Solution
A power unit room installing structure that includes a charging cable routed towards a dash panel, covered by a regulating cable to restrict movement and overlap with a high voltage component, using a transaxle-charger connecting cable as the regulating cable to secure extra length and protect against electric shock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If many components are installed in the power unit room to meet the functional requirements of PHEVs and EVs, then the functionality and power of the vehicle are improved, but the available empty space in the power unit room is reduced, making it difficult to provide safety buffers around high voltage components
Solution Approach 1:
The charging cable is routed in advance through the power unit room towards the dash panel, and the regulating cable is pre-installed to cover and restrict the charging cable's movement. This preliminary arrangement ensures that when a collision occurs, the charging cable is already positioned to cover the high voltage component, preventing secondary accidents without requiring additional empty space in the power unit room.
2Ease of operation
If the charging cable is allowed to move freely in the power unit room, then the ease of operation and charging functionality are improved, but the risk of secondary accidents from exposed high voltage components during collisions increases
Solution Approach 1:
The regulating cable changes the movement parameters of the charging cable by restricting movement in the vehicle upward side direction while allowing movement toward the dash panel. This selective parameter control enables the charging cable to maintain charging functionality while simultaneously providing protective coverage over the high voltage component during collisions.
Solution Approach 2:
The regulating cable acts as an intermediary element between the charging cable and the high voltage component. It covers the charging cable from the vehicle upward side, using the charging cable itself as a protective barrier over the high voltage component, thereby eliminating the need for additional protective structures.
3Reliability
If a regulating cable is installed to cover and restrict the charging cable movement, then the safety against secondary accidents is improved, but the device complexity increases
Solution Approach 1:
The regulating cable serves multiple functions simultaneously: it restricts the charging cable's movement to prevent excessive displacement during collisions, covers the charging cable to create a protective layer over the high voltage component, and allows necessary movement for charging operations. This multi-functionality reduces the need for separate protective devices, thereby limiting the increase in device complexity.
Solution Approach 2:
The function of protecting the high voltage component is merged with the existing charging cable system. Instead of adding a separate protective cover or barrier, the charging cable itself is utilized as the protective element by positioning it over the high voltage component through the regulating cable's restriction, combining protection and charging functions in one system.
4Ease of operation
If the charging cable is routed towards the dash panel, then the ease of operation for charging is improved, but the charging cable may move upward during collisions, exposing the high voltage component
Solution Approach 1:
The regulating cable applies localized restriction to the charging cable at the position where it passes through the power unit room towards the dash panel. It specifically restricts movement in the vehicle upward side direction while allowing movement toward the dash panel, creating different movement characteristics in different directions to simultaneously ensure charging accessibility and collision safety.
Data Source
AI summary
The power unit room installing structure includes: a power unit disposed opposite to the dash panel in the vehicle front-rear direction; a high voltage component disposed between the power unit and the dash panel; a charger disposed on the vehicle upper side of the power unit; a charging cable disposed from the charger toward the dash panel; and a regulating cable that is another cable different from the charging cable, wherein a part of the charging cable is covered from the vehicle upper side, thereby restricting movement of the charging cable toward the vehicle upper side and allowing movement toward at least the dash panel side.