Vehicle Power Distribution Unit Layout for Shorter HV Cable Runs
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Solution Overview
Problem
Existing vehicles with electrical energy systems face challenges in efficiently distributing electrical energy to motors and secondary electrical loads due to complex cable configurations and limited space within the vehicle chassis.
Innovation Solution
A power distribution unit is positioned within the volume defined between the cab and the body of the vehicle, directing electrical energy from the battery to the electric motor and secondary electrical loads, optimizing energy distribution and reducing cable complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the power distribution unit is positioned in the volume between the cab and the body, then the cable length is minimized and energy distribution efficiency is improved, but the space availability for other components is reduced
Solution Approach 1:
The power distribution unit is positioned in the longitudinal dimension between the cab and body, utilizing the available space in this dimension rather than competing for lateral or vertical space. This dimensional placement optimizes cable routing while maintaining space availability in other dimensions for additional components.
2Loss of energy
If the power distribution unit is centrally located to minimize cable length, then energy distribution efficiency is improved, but the complexity of vehicle configuration is increased
Solution Approach 1:
The power distribution unit is designed with a universal mounting configuration that can adapt to different vehicle layouts. The unit incorporates multiple connection points and flexible cable routing options, allowing it to serve as a central hub while maintaining ease of configuration across various vehicle models and applications.
3Ease of repair
If the power distribution unit is positioned in the volume between the cab and the body, then maintenance access is improved, but the structural integrity of the vehicle frame may be compromised
Solution Approach 1:
The power distribution unit is mounted on a separate support structure or bracket that attaches to the frame rails, rather than directly modifying the main vehicle frame. This segmentation allows the unit to be easily removed for maintenance while preserving the structural integrity of the original frame design.
Data Source
AI summary
A vehicle includes a chassis, a tractive element coupled to the chassis, a cab coupled to the chassis and configured to support an operator, a body coupled to the chassis and offset longitudinally rearward from the cab, such that a volume is defined between the cab and the body, an electric motor configured to drive the tractive element to propel the vehicle, a secondary electrical load, a battery configured to supply electrical energy, and a power distribution unit configured to direct the electrical energy from the battery to the electric motor and the secondary electrical load. The power distribution unit is positioned in the volume defined between the cab and the body.