Vehicle Control Unit Support Frame Diagonal Displacement Mechanism
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Solution Overview
Problem
The high rigidity of power control units in vehicles to absorb collision energy leads to increased weight, limiting design freedom and efficiency in frontal collision scenarios.
Innovation Solution
A supporting structure with a frame main body of L-shape, featuring a side edge and rear edge design that allows diagonal displacement upon collision, reducing load input and maintaining wire connections, thereby optimizing the power control unit's weight and design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power control unit is designed with increased strength to prevent damage during collision, then reliability is improved, but weight increases
Solution Approach 1:
The supporting frame acts as an intermediary between the power control unit and the collision load. It includes a deformation member that absorbs collision energy through controlled deformation, and a load transmission member that directs forces away from the power control unit, thereby protecting it without requiring the unit itself to be heavily reinforced
Solution Approach 2:
The supporting frame is designed with a deformation member that is pre-configured to deform during collision to absorb impact energy before it reaches the power control unit. This beforehand cushioning protects the power control unit from damage without requiring the unit to be designed with excessive strength
2Reliability
If the power control unit is made heavier with increased strength, then reliability is improved, but design freedom is reduced
Solution Approach 1:
The supporting frame serves as a mediator that handles collision protection functions, allowing the power control unit to be designed based on functional requirements rather than being constrained by weight and strength considerations. This separation of concerns restores design freedom
Solution Approach 2:
The supporting frame is segmented into distinct functional components: a deformation member for energy absorption, a load transmission member for force direction, and connection members for structural integration. This segmentation allows each component to be optimized independently while protecting the power control unit
3Reliability
If the supporting frame uses rigid connection to protect the power control unit, then reliability is improved, but the frame cannot absorb collision energy effectively
Solution Approach 1:
The deformation member is pre-designed to deform in a controlled manner during collision, absorbing impact energy before it reaches the power control unit. This beforehand cushioning enables effective energy absorption while maintaining protection capability
Solution Approach 2:
The supporting frame utilizes parameter changes in the deformation member, which transitions from a rigid state during normal operation to a deformable state during collision. This parameter change allows the frame to absorb collision energy effectively while maintaining reliability
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 supporting structure effectively reduces upward displacement of the power control unit during a frontal collision, simplifies wire connections, and minimizes contact with other components, resulting in a lighter and more optimized design.
Implementation Method 1
the front connection part deforms before the side edge part, the rear connection part, and the rear end frame member
Implementation Method 2
the front connection part deforms before the side edge part
Implementation Method 3
this pressing causes the rear connection part to rotationally displace, to thereby displace the supporting frame and the power control unit diagonally rear-downward
Data Source
AI summary
An inner side edge part of a PCU supporting frame is arranged at a rear-downward angle; a rear supporting bracket that connects a rear edge part of the supporting frame with a dashboard upper is arranged at a rear-upward angle; the frame main body and the PCU are pressed diagonally down-backward when a load input is received on the supporting frame from the vehicle front side; and with the rear supporting bracket being rotationally displaced by this pressing, the supporting frame and the PCU are displaced diagonally down-backward.