Vehicle High-Voltage Cable Routing Along Motor Case
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Solution Overview
Problem
In electric vehicles, the routing of high-voltage cables often results in noise generation and abnormal heating due to close proximity to low-voltage harnesses, requiring a compact routing structure that secures a sufficient curvature radius and withstands vibration while minimizing electromagnetic interference.
Innovation Solution
The high-voltage cable is connected to the motor's end surface and routed along the motor case in a J-shape, with protectors supporting the cable to maintain a secure curvature radius and reduce vibration and noise interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the high-voltage cable is routed close to the low-voltage harness to reduce cable length, then the cable length is reduced, but electromagnetic noise generation increases
Solution Approach 1:
The high-voltage cable routing is extracted from the conventional center path and redirected to follow the motor case periphery, separating it from the low-voltage harness routing area. This spatial extraction eliminates electromagnetic interference while maintaining cable length efficiency.
Solution Approach 2:
The cable routing transitions from a two-dimensional planar path along the vehicle center to a three-dimensional path that utilizes the vertical and lateral dimensions by following the motor case contours, enabling compact routing without electromagnetic interference.
2Loss of energy
If the curvature radius of the high-voltage cable is increased to prevent abnormal heating, then power loss is reduced, but the routing space requirement increases
Solution Approach 1:
The high-voltage cable is nested along the motor case periphery, utilizing the existing motor housing contours as a guide path. This nesting approach allows the cable to follow a smooth curved path with adequate radius while occupying minimal additional space within the motor assembly area.
Solution Approach 2:
The cable routing emphasizes smooth curved paths rather than sharp angles, following the rounded contours of the motor case. This curvature-based routing ensures adequate bend radius to prevent internal resistance increases and abnormal heating, while the curved path efficiently utilizes available space.
3Reliability
If the high-voltage cable is routed to accommodate motor vibration and movement, then vibration resistance is improved, but the routing structure complexity increases
Solution Approach 1:
The cable routing is merged with the motor case structure, using the motor housing itself as the routing guide and protective barrier. This integration allows the cable to naturally accommodate motor vibration and movement through the flexible yet protected path along the motor case, without requiring separate complex routing structures.
Solution Approach 2:
The cable routing employs flexible protective coverings that can accommodate motor vibration and positional changes. These flexible elements allow the cable to move with the motor during operation while maintaining electrical connection and protection, simplifying the overall routing structure compared to rigid constrained systems.
Data Source
AI summary
A routing structure of a high-voltage cable of a vehicle has a high-voltage cable (18) connected to an end surface of a motor (10) and routed along a motor case (13) by being extended from the connecting portion in one direction and then extended in the direction reverse to the one direction, and in which structure a first protector (41) configured to hold the high-voltage cable (18) and extended along the motor case (13) is supported on the motor case (13).