Packaging of high voltage cable through the underbody of a hybrid vehicle using CAE simulation tools

Abstract

One of the major concerns for Hybrid and electric cars would be its overall crash safety performance. Besides the structural integrity of the vehicle and High voltage battery enclosure, the routing of the High Voltage (HV) cable is important. The packaging of the cable is based on two main factors namely its operational functionality and safety from crash impacts. The functioning of the cable depends on the robustness of the material of the HV cable, basic shielding from external environments and the radii of cable bending at different locations. The second factor, safety is extremely crucial as any rupturing of the HV cable during a crash event would expose it to the vehicle body which could result in electrocution of the occupant and extensive damage to the vehicle. A Methodology is showcased in which virtual simulation tools is used to address the safety concerns with respect to high voltage cable during any crash event. The primary step was to identify the zone throughout the underbody to route the HV cable, which would be safe in crash events like frontal, side and rear. Different crash scenarios were simulated using a Finite element model to arrive at safe zone for routing HV cable. Each simulation was carefully studied to understand the interaction of other systems with the High voltage cable, displacement of cable during the crash event and these inputs were taken to conceptualize packaging of the cable around the subsystems and vice versa. Hence this robust approach was evolved to propose safe packaging of the high voltage cable in the hybrid vehicle.