Electric Suspension Wiring Layout for High-Voltage Collision Isolation
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Solution Overview
Problem
Existing electric suspension apparatuses in vehicles face safety challenges due to high voltage components, particularly during collisions, as they lack effective mechanisms to ensure safe disconnection and voltage suppression in case of abnormalities in signal and low voltage lines.
Innovation Solution
The design incorporates a configuration where the signal and low voltage lines are arranged to be shorter than the high voltage lines, with a control device that suppresses high voltage supply to the electric actuator in case of abnormalities, and are positioned to disconnect before the high voltage lines, ensuring safer operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the high voltage line is made longer to reach the high voltage component, then the electrical connection is ensured, but the safety during collision is deteriorated because the high voltage line may not disconnect before other lines
Solution Approach 1:
The signal line and low voltage line are designed with shorter lengths than the high voltage line, so that in case of collision, these lines disconnect first before the high voltage line. This preliminary disconnection action prevents high voltage from reaching the component, eliminating the harmful effect while maintaining reliable electrical connection during normal operation.
2Object-affected harmful factors
If the signal line and low voltage line are made shorter than the high voltage line, then the collision safety is improved by ensuring earlier disconnection, but the wiring complexity increases
Solution Approach 1:
The wiring system is segmented into three distinct groups based on function and safety requirements: signal lines, low voltage lines, and high voltage lines. Each group has differentiated length characteristics, with signal and low voltage lines being shorter than the high voltage line. This segmentation creates a hierarchical safety structure that improves collision safety while maintaining manageable wiring complexity through functional grouping.
3Reliability
If the control device suppresses high voltage supply upon detecting abnormality, then the safety is improved, but the response time depends on abnormality detection capability
Solution Approach 1:
The system employs dual safety mechanisms: (1) Physical preliminary action through differentiated line lengths that cause automatic disconnection of signal and low voltage lines before high voltage lines during collision; and (2) Control preliminary action where the control device suppresses high voltage supply upon detecting abnormality. These preliminary actions work together to ensure safety while minimizing response time through both passive physical design and active control monitoring.
Data Source
AI summary
A vehicle includes a high voltage component such as an electric actuator, an electric suspension control ECU, a battery, a signal line which transmits, to the electric suspension control ECU, a detection signal of a sensor disposed in the electric actuator, a high voltage line which supplies a high voltage from the battery to the electric actuator, and a fixing member which fixes the signal line and the high voltage line to a vehicle body, a length of the signal line from the fixing member to the electric actuator is shorter than a length of the high voltage line from the fixing member to the electric actuator, and the electric suspension control ECU suppresses the supply of the high voltage to the electric actuator, in a case where abnormality occurs in the signal line.