Vehicle Power Cable Holding Structure Using Nested Protective Pipes
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Solution Overview
Problem
In electric vehicles, the large diameter and heavy load of power cables pose challenges in minimizing space usage above the floor and enhancing workability during installation, while also requiring efficient routing and protection.
Innovation Solution
A power cable holding structure that uses a metal protective pipe to accommodate power cables of different diameters, with smaller cables inserted between larger cables and the pipe's inner surface, allowing efficient routing under the floor and providing electromagnetic shielding for nonshielded cables, along with flexible tubes and braided shields for vibration absorption and grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If power cables are routed above the floor in the cabin space, then installation and maintenance are easier, but the cabin space is reduced and the vehicle interior is cramped
Solution Approach 1:
The patent transitions the cable routing from the vertical dimension (above the floor in cabin space) to the horizontal dimension (under the floor in the space between floor and vehicle frame). This dimensional change allows cables to be routed away from the cabin interior, preserving headroom and living space while maintaining accessibility for installation and maintenance through access panels or service points.
2Reliability
If a large diameter protective pipe is used to accommodate all power cables, then all cables are protected, but the pipe size and weight increase
Solution Approach 1:
The patent segments the cable routing system into multiple smaller protective pipes, each dedicated to specific cables or cable groups. This segmentation allows each pipe to be optimized for its specific cable bundle, reducing the overall material required compared to a single large pipe. The segmented approach also enables independent installation and replacement of individual cable bundles without handling the entire cable system.
Solution Approach 2:
The patent employs nested protective piping where smaller protective pipes containing specific cables are inserted within or alongside larger protective pipes. This nested structure provides multi-level protection: inner pipes protect individual cable bundles, while outer pipes provide additional protection for the entire assembly. The nested design optimizes space utilization and reduces the total weight compared to using a single oversized pipe.
3Object-affected harmful factors
If shielded cables are used for electromagnetic protection, then electromagnetic interference is reduced, but the cable diameter and weight increase
Solution Approach 1:
The patent extracts the electromagnetic shielding function from the cable structure itself and relocates it to the protective pipe system. By using conductive or metallic protective pipes that can be grounded, the shielding function is separated from the cable insulation layers. This allows the use of simpler, lighter non-shielded cables while maintaining electromagnetic interference protection through the external protective piping structure.
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 solution minimizes the size and weight of the protective pipe, enhances workability by laying cables under the floor, prevents cabin space cramping, and allows the use of nonshielded cables, while ensuring electromagnetic shielding and grounding.
Implementation Method 1
the metal protective pipe functions as an electromagnetic shield, thereby enabling the adoption of nonshielded cables as the power cables
Implementation Method 2
The protective tubes can absorb dimensional errors arising from laying of the power cables as well as prevent the transmission of engine vibrations and the like to the protective pipe
Data Source
AI summary
A power cable holding structure for a vehicle in which compressor power cables having a small outer diameter are disposed in the gaps between the outer surface of motor power cables having a large outer diameter and the inner surface of a protective pipe. Also, a method of assembling a power cable assembly comprising the steps of: inserting the other end side of the power cables with first connectors attached into one end portion into the protective pipe; disposing the small diameter compressor power cables in the gaps between the outer surface of the large diameter power cables and the inner surface of the protective pipe; and after applying bending work to the protective pipe in this state, adjusting the lengths of the other end portions of the power cables and attaching second connectors.