Smart Vehicle Control Unit Integration and Wiring Reduction
Solution Overview
Problem
Conventional smart vehicles face challenges in mounting control units without increasing vehicle dimensions, leading to cumbersome wiring harness routing, voltage drops, and electromagnetic interference (EMI) issues, which hinder accessibility and maintainability of control units.
Innovation Solution
The smart vehicle design positions control units, such as the EMS-ECU and ISG controller, between the front and rear panels with a storage enclosure, utilizing a mounting enclosure with cooling fins and air vents for effective cooling, and routing high-voltage wiring harnesses behind the storage enclosure to reduce length and interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If control units are mounted on the frame structure at different locations, then the vehicle can accommodate multiple control units, but the wiring harness length increases causing voltage drop and EMI
Solution Approach 1:
The patent combines multiple control units (EMS-ECU, ISG controller, relay unit, protection device) into a single integrated control unit assembly mounted at one location on the vehicle frame. This merging eliminates the need for long wiring harnesses connecting distributed control units, thereby reducing voltage drop and EMI while maintaining the ability to accommodate all required control functions.
2Loss of energy
If control units are positioned in close proximity to reduce wiring length, then voltage drop is reduced, but accessibility and maintainability of control units deteriorates
Solution Approach 1:
The patent segments the control unit assembly into a mounted assembly portion (containing control units) and a separate serviceable portion (relay unit and protection device). The relay unit and protection device are mounted on the control unit assembly but are designed to be independently accessible and serviceable, allowing maintenance without removing the entire assembly from the vehicle frame.
3Adaptability or versatility
If control units are mounted on the frame structure, then the vehicle can support multiple control units, but the layout complexity of wiring harness and connections increases
Solution Approach 1:
The patent merges multiple control units into a single integrated assembly with centralized mounting. The relay unit and protection device are integrated into this assembly, creating a compact module that requires minimal wiring harness connections to the vehicle frame. This significantly simplifies the overall wiring harness layout compared to distributing control units throughout the vehicle.
4Loss of energy
If control units are positioned between front and rear panels with storage enclosure, then wiring length is reduced and EMI is mitigated, but heat dissipation becomes challenging
Solution Approach 1:
The patent introduces cooling fins as an intermediary heat dissipation mechanism between the control units and the surrounding environment. The cooling fins increase the surface area for thermal radiation and convection, enabling effective heat dissipation from the control units mounted in the constrained space between the front panel, rear panel, and storage enclosure.
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
This configuration reduces wiring harness length, minimizes voltage drops, and mitigates EMI, enhancing serviceability, maintainability, and heat dissipation, while maintaining control unit performance and reducing manufacturing costs.
Implementation Method 1
routing high-voltage wiring harnesses behind the storage enclosure to reduce length and interference
Implementation Method 2
mounting enclosure with cooling fins and air vents for effective cooling
Data Source
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AI summary
A smart vehicle is disclosed comprising a front panel (200), a rear panel (304) proximal to a seat of the smart vehicle, and a storage enclosure (301) for accommodating at least one energy storage device. The storage 5 enclosure (301) is disposed in a space between the front panel (200) and the rear panel (304). At least one control unit (302, 303) is positioned in the space between the front panel (200) and the rear panel (304) and the at least one control unit (302, 303) is mounted to the rear panel (304).