Terminal Cover Interlock via Sub-Battery Positioning
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Solution Overview
Problem
Existing vehicle drive motor systems require a safety interlock mechanism to prevent high-voltage electric power supply when the terminal cover is removed, but this typically necessitates incorporating a switch or interlock device within the terminal cover, which complicates the structure.
Innovation Solution
The system employs a sub-battery positioned adjacent to the controller to interfere with the removal of the terminal cover, acting as an interlock by cutting off the high-voltage power supply path when the sub-battery is removed, thus eliminating the need for a separate interlock device within the terminal cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a switch or interlock device is incorporated within the terminal cover to prevent high-voltage power supply when the cover is removed, then safety is improved, but device complexity increases
Solution Approach 1:
The interlock function is extracted from the terminal cover and relocated to the controller body. The terminal cover no longer needs to incorporate switches or interlock devices, as the controller itself provides the interlock functionality through its internal relay control mechanism. This extraction simplifies the terminal cover structure while maintaining safety requirements.
Solution Approach 2:
The controller is given multiple functions: it not only controls the motor but also serves as the interlock device by controlling the relay that cuts off high-voltage power supply. This multi-functionality eliminates the need for separate interlock components in the terminal cover, reducing overall device complexity while maintaining safety.
2Ease of operation
If the terminal cover is designed to be easily removable for maintenance, then ease of operation is improved, but safety is compromised without an interlock mechanism
Solution Approach 1:
The system performs preliminary action by automatically cutting off high-voltage power supply through the relay before the maintenance worker actually removes the terminal cover. The controller detects the cover removal state and preemptively disables power supply, ensuring safety is maintained while allowing easy removal of the cover for maintenance purposes.
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 simplifies the interlock mechanism, ensuring safe disconnection of high-voltage power without requiring additional components within the terminal cover, enhancing safety and reducing structural complexity.
Implementation Method 1
a sub-battery that supplies electric power to the relay
Implementation Method 2
a relay that is interposed in an electric power supply path extending from the main battery to the controller and that is normally open
Data Source
AI summary
An automobile includes: a controller for controlling a motor; a main battery for supplying electric power to the motor via the controller; a normally open relay interposed in an electric power supply path extending from the main battery to the controller; and a sub-battery for supplying the electric power to the relay. The controller is mounted with a terminal cover that covers an output terminal for connection with a power supply cable to the motor. The sub-battery is disposed adjacent to the controller so as to interfere with the removal of the terminal cover by a worker.