Modularized automobile wire harness system based on high-density integrated wiring and design method thereof

Abstract

The invention provides a modular automobile wire harness system based on high-density integrated wiring and a design method thereof.The modular automobile wire harness system comprises a center console PCB automobile wire harness system and a trunk PCB automobile wire harness system, the center console PCB automobile wire harness system comprises a center console PCB, the trunk PCB automobile wire harness system comprises a trunk PCB, and the trunk PCB is connected with the center console PCB. The center console PCB and the luggage case PCB are respectively provided with a connector, the center console PCB and the luggage case PCB are respectively arranged in a PCB protection shell, and the center console PCB is connected with the luggage case PCB through an FFC (Flexible Flat Cable) connector. Meanwhile, the invention further discloses a design method of the modular automobile wire harness based on high-density integrated wiring, the chassis wire harness can be divided into different independent units based on the modular partition design of the PCB, and the segmented assembly and modular process is achieved; through the design of the shielding layer, the signal integrity is optimized, and the anti-interference capability is improved; the modularized PCB chassis wire harness is flexible in later expansion and convenient to maintain.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile manufacturing, and in particular to a modular automobile wiring harness system based on high-density integrated wiring and a design method thereof. Background Art

[0002] Throughout the development of the automotive industry, automotive wiring harnesses are key components that connect various electronic devices and sensors in a vehicle. Traditional automotive wiring harnesses consist of a large number of wires, connectors, and insulation materials. Their design and manufacturing technologies have long met the needs of automotive production and use. However, with the increasing electronicization and intelligence of vehicles, an increasing number of electronic systems are being integrated into vehicles, such as engine control systems, braking systems, and entertainment systems. These systems require a large number of wiring harnesses to transmit power and signals to ensure the proper functioning of all components. This results in heavy and bulky automotive wiring harnesses, hindering vehicle lightweighting and overall chassis layout, poor signal integrity, difficulty in expansion and modification, and complex assembly processes. Therefore, a modular automotive wiring harness system based on high-density integrated wiring is proposed.

[0003] Patent application number 202211107896.4 discloses a lightweight design method for automotive wiring harnesses. This method includes optimizing wiring harness topology, electrical component placement and control schemes, accessory selection, materials, and processes. It also includes a method for evaluating the implementation of various lightweighting schemes during wiring harness design, using lightweight price-to-weight ratios and product technology maturity as criteria. This invention effectively reduces wiring harness weight and provides a practical evaluation method. The patent utilizes Ethernet, CAN bus, and LIN line technologies to enable the transmission of more signals, reducing the number of control signal loops, ensuring impedance matching across the vehicle network, and preventing signal reflections. Terminal resistors are designed into standard nodes and placed at the farthest end of the vehicle wiring harness. The length of the bus spurs must meet standard requirements, and the wiring harness routing is rationally planned to avoid tangles. However, the system still consists of multiple independent wires bundled together, resulting in a large overall size and complex layout, making it difficult to flexibly adapt to compact spaces. Furthermore, it struggles to meet the requirements of modular assembly and easy expansion. Summary of the Invention

[0004] In response to the technical problem of low integration of existing chassis wiring harnesses, the present invention proposes a modular automotive wiring harness system based on high-density integrated wiring and its design method. By using PCB to replace the automotive wiring harness, a flat layout of the wiring harness path is achieved, which reduces weight, compresses space, and is more suitable for the requirements of lightweight automobiles.

[0005] In order to achieve the above-mentioned purpose, the technical solution of the present invention is implemented as follows: a modular automotive wiring harness system based on high-density integrated wiring, including a center console PCB automotive wiring harness system and a trunk PCB automotive wiring harness system, the center console PCB automotive wiring harness system includes a center console PCB, the trunk PCB automotive wiring harness system includes a trunk PCB, both the center console PCB and the trunk PCB are provided with connectors, the center console PCB and the trunk PCB are respectively arranged in a PCB protective shell, and the center console PCB and the trunk PCB are connected by FFC.

[0006] Preferably, the PCB protection shell includes at least two sections of an upper shell and a lower shell, adjacent lower shells are connected by a guide hanging structure, and the upper shell and the lower shell are quickly positioned and pre-assembled by a pre-installed guide structure.

[0007] Preferably, the bottom layers of the center console PCB and the trunk PCB are provided with a CAN line, a GND shielding layer is designed around the CAN line and on the second bottom layer of the PCB board, the wiring gaps of other layers of the PCB board are filled with the GND shielding layer, and each layer of the PCB board is provided with a through hole connected to the GND shielding layer.

[0008] A design method for a modular automotive wiring harness system based on high-density integrated wiring, the steps of which are as follows: Step S1: Divide the chassis wiring harness system into a center console PCB wiring harness system and a trunk PCB wiring harness system according to the regional distribution and connection relationship of the wiring harness. Step S2: Based on the number of wiring harnesses required for the center console PCB automotive wiring harness system and the trunk PCB automotive wiring harness system, select the appropriate connector type, and design the number of PCB layers, trace width, and CAN line routing path to obtain the center console PCB and the trunk PCB respectively; Step S3: Designing a PCB protective housing based on the size, connector location, and installation environment of the center console PCB and the trunk PCB; Step S4: Install the PCB protective housing, the center console PCB, and the trunk PCB in the actual vehicle, and connect the center console PCB and the trunk PCB through a connector and FFC.

[0009] Preferably, the center console PCB is provided with five sets of 30-wire connectors, six sets of 40-wire connectors, one set of 24-wire connectors, and two sets of FFC-specific 48-wire connectors; the trunk PCB is provided with one set of 30-wire connectors, two sets of 40-wire connectors, and two sets of FFC-specific 48-wire connectors; the connectors provide pluggable connections between a large number of electronic devices and electronic control units in the car; The center console PCB adopts a 6-layer design and a PCB thickness of 1.6 mm; the trunk PCB 16 of the trunk PCB automobile wiring harness system 2 adopts a four-layer design and a PCB thickness of 1.6 mm.

[0010] Preferably, the required trace width is designed according to the current size passing through the loop: when the current is less than 1A, the trace width is designed to be 1.5mm; when the current is greater than 1A, the trace width is designed according to the formula trace width (mm) = current (A) × 1.5; The CAN line has a milliampere current and is routed using a 0.4mm line width with a large margin.

[0011] Preferably, the CAN line is routed on the bottom layer of the PCB board, following the routing principle of line spacing greater than 3 times the line width and the shortest routing path principle; the routing spacing of different groups of CAN lines in the center console PCB automotive wiring harness system and the trunk PCB automotive wiring harness system are both greater than 3 times the line width, and are appropriately widened according to the space margin; the line spacing between the same group of CAN lines is greater than 3 times the line width.

[0012] Preferably, the center console PCB automotive wiring harness system has a GND shielding layer designed around the CAN line and on the sub-bottom layer. Conventional wiring harnesses are routed on layers 1-4, with the GND shielding layer filling the gaps between conventional wiring harnesses. Through-holes are placed on both sides of the CAN line to connect the GND shielding layers between different layers. The trunk PCB automotive wiring harness system 2 has a GND shielding layer designed around the CAN line and on the sub-bottom layer. Conventional wiring harnesses are routed on layers 1-2, with the GND shielding layer filling the gaps between conventional wiring harnesses. Through-holes are placed on both sides of the CAN line to connect the GND shielding layers between different layers.

[0013] Preferably, the PCB protection housing is a three-section housing having a pre-installed guide structure and a guide hanging structure; The PCB protection housing comprises a three-section upper housing and a three-section lower housing. The connections between adjacent sections of the lower housing are designed with a guide and hook structure that engages with each other. Pre-installed guide structures are provided on the upper and lower housings to enable rapid positioning of the upper and lower housings. The upper housing, the center console PCB or the luggage compartment PCB and the lower housing are fastened together from top to bottom; The lower shell is provided with a detachable mounting bracket, which is connected to the vehicle body.

[0014] Preferably, the center console PCB automotive wiring harness system connects and clocks in the relevant wiring harnesses in the front and middle areas of the car; the trunk PCB automotive wiring harness system connects and clocks in the relevant wiring harnesses in the rear of the car; the CAN line is a key line in the automotive wiring harness for communication between control units; the center console PCB automotive wiring harness system and the trunk PCB automotive wiring harness system are connected through FFC connectors; the connectors on the center console PCB automotive wiring harness system and the trunk PCB automotive wiring harness system are respectively connected to the wiring harnesses of the vehicle functional modules through corresponding connectors in a plug-in manner; The guide and hanging structure includes a first locking structure and a first guide rail, wherein the first guide rail is provided on both sides of one end of a lower shell, and the first locking structure is provided on the lower shell and in the middle of another adjacent lower shell, and the first locking structure is located between the first guide rails; The first locking structure includes a positioning hole and a lock buckle, the positioning hole is adapted to the lock buckle, and the end of the lock buckle is provided with a protrusion that engages with the positioning hole. The lock buckle is provided at one end of the lower shell, and the positioning hole is provided at the other end of the adjacent lower shell sections to be spliced; The pre-installed guide structure includes matching protrusions and grooves, the protrusions are provided on the upper shell, and the grooves are provided on the lower shell at corresponding positions; The mounting bracket includes a fixing foot fixedly connected to the vehicle body; the fixing foot is fixed to the lower part of the fixing plate, and a second locking structure is provided between the fixing plate and the lower shell. The upper portion of the fixed plate is provided with a second guide rail, and the lower shell is provided with a guide groove, and the second guide rail is slidably connected to the guide groove; the second locking structure includes a hanging platform and a second lock buckle, the upper portion of the fixed plate is provided with the second lock buckle, and the lower portion of the lower shell is provided with a hanging platform; the hanging platform is adapted to the second lock buckle; The end of the second lock buckle is provided with a protrusion that is engaged with the hanging platform.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: by adopting PCB to replace the traditional wiring harness, a flat layout of the wiring harness path is achieved, the space layout of the automobile chassis is optimized, and the volume and weight of the vehicle are reduced; secondly, the shielding layer design, 3W routing principle and shortest routing path principle followed by the CAN line during the design process ensure the stable transmission of the signal, which helps to improve the intelligence level of the entire vehicle. Furthermore, the modular partition design based on the PCB improves the assembly process, improves production efficiency and quality, facilitates expansion and changes, and enhances the adaptability and maintainability of the vehicle. The present invention is based on the modular partition design of the PCB, and the chassis wiring harness can be divided into different independent units to realize segmented assembly and modular process; through the shielding layer design, the signal integrity is optimized and the anti-interference ability is improved; the modular PCB chassis wiring harness is flexible for later expansion and easy to maintain. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0017] Figure 1 Flowchart of the design method of the present invention.

[0018] Figure 2 This is an exploded view of the automotive wiring harness system of the present invention.

[0019] Figure 3 This is a schematic diagram of the shielding layer design around the CAN line of the present invention.

[0020] Figure 4 Schematic diagram of the guide hanging structure of the PCB protection shell of the present invention, wherein (a) is before hanging, and (b) is after buckling.

[0021] Figure 5 Schematic diagram of the pre-installed guide structure of the present invention.

[0022] Figure 6 Schematic diagram of the mounting bracket of the present invention, wherein (a) is a three-dimensional diagram, (b) is a top view, and (c) is a bottom view.

[0023] In the figure, 1 is the center console PCB automobile wiring harness system, 2 is the trunk PCB automobile wiring harness system, 3 is the bottom layer, 4 is the 30-wire connector, 5 is the 40-wire connector, 6 is the 24-wire connector, 7 is the 48-wire connector, 8 is the FFC, 9 is the self-tapping screw, 10 is the pre-installed guide structure, 11 is the guide hanging structure, 12 is the upper shell, 13 is the lower shell, 14 is the center console PCB, 15 is the mounting bracket, 16 is the trunk PCB, 17 is the CAN line, 18 is the through hole, 111 is the first locking structure, 112 is the first guide rail, 113 is the first lock buckle, 114 is the positioning hole, 101 is the protrusion, 102 is the groove, 151 is the second guide rail, 152 is the second locking structure, 153 is the fixing foot, 154 is the hanging platform, and 155 is the second lock buckle. DETAILED DESCRIPTION

[0024] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without creative work are within the scope of protection of the present invention.

[0025] Example 1 like Figure 1 As shown, a design method for a modular automotive wiring harness system based on high-density integrated wiring uses a PCB (Printed Circuit Board) to replace the traditional automotive wiring harness, including the following steps: Step S1: Divide the chassis wiring harness system into a center console PCB wiring harness system 1 and a trunk PCB wiring harness system 2 according to the regional distribution and connection relationship of the wiring harness.

[0026] The center console PCB automotive wiring harness system 1 primarily connects and clocks in wiring harnesses for the engine, instrument panel, and doors, among other areas in the vehicle's mid-front region. The trunk PCB automotive wiring harness system 2 primarily connects and clocks in wiring harnesses for the tailgate, air curtains, taillights, and other areas of the vehicle's rear.

[0027] Based on a modular PCB design, the chassis wiring harness can be divided into independent sub-board units according to their functions. During design, it is divided into a center console PCB wiring harness system 1 and a trunk PCB wiring harness system 2. The sub-board units can also be divided into different independent sub-board units according to different functions. The center console PCB wiring harness system 1 and the trunk PCB wiring harness system 2 are connected via a dedicated connector and a flexible flat cable (FFC).

[0028] PCB trace width directly affects the resistance and temperature rise of current flowing through the loop. Under the same material conditions, wider trace widths reduce resistance and generate less heat when current flows through them. Therefore, both the center console PCB automotive wiring harness system 1 and the trunk PCB automotive wiring harness system 2 require appropriate trace widths designed based on the current flowing through the loop.

[0029] CAN (Controller Area Network) cables are key lines in automotive wiring harnesses for communication between control units. Measures such as shielding and spacing three times the line width are necessary to prevent interference. Routing should be done appropriately, minimizing excessive lengths and bends to minimize signal attenuation. For wiring harnesses other than CAN cables, no additional interference mitigation is required; simply design the appropriate trace width based on the current flowing through the circuit.

[0030] Step S2: According to the number of wiring harnesses required for the center console PCB automotive wiring harness system 1 and the trunk PCB automotive wiring harness system 2, select the appropriate connector type, and design the number of PCB layers, trace width, and CAN line trace path to obtain a PCB board.

[0031] In the present invention, the center console PCB automotive wiring harness system 1 has approximately 500 circuits and utilizes five sets of 30-wire connectors 4, six sets of 40-wire connectors 5, one set of 24-wire connectors 6, and two sets of FFC-specific 48-wire connectors 7. In the present invention, the trunk PCB automotive wiring harness system 2 has approximately 150 circuits and utilizes one set of 30-wire connectors 4, two sets of 40-wire connectors 5, and two sets of FFC-specific 48-wire connectors 7. The number of pins for the 30-wire connectors 4, 40-wire connectors 5, 24-wire connectors 6, and FFC-specific 48-wire connectors 7 is selected based on the number of wiring harness circuits; they serve to achieve pluggable connections between a large number of electronic components and electronic control units in the vehicle. Connector placement is primarily determined by: ease of routing during PCB design; and minimizing the distance between the electronic components and the board. For example, the connector for the left door wiring harness should be placed as far to the left of the PCB after installation as possible.

[0032] The number of copper foil layers in a PCB automotive wiring harness system can be flexibly selected based on the number of wiring harnesses. At the beginning of the design, the number of wiring harnesses should be evaluated. If the number of wiring harnesses is small, a four-layer PCB design is preferred. If the number of wiring harnesses is large and routing is more challenging, a six-layer PCB design is considered to facilitate routing. Center console PCB automotive wiring harness system 1 has approximately 500 circuits. Due to the large number of circuits, center console PCB 14 of center console PCB automotive wiring harness system 1 adopts a six-layer design with a PCB thickness of 1.6 mm. Trunk PCB automotive wiring harness system 2 has approximately 150 circuits, with a smaller number of circuits. Trunk PCB 16 of trunk PCB automotive wiring harness system 2 adopts a four-layer design with a PCB thickness of 1.6 mm.

[0033] The PCB in the center console wiring harness system 1 weighs 400.5 g, while the PCB in the trunk chassis system 2 weighs 441.6 g. Compared to traditional automotive wiring harnesses, this system reduces copper content by 64% to 76%, significantly reducing vehicle weight and optimizing chassis space.

[0034] In traditional automotive wiring harnesses, signal interference and loss between wires can easily cause signal distortion, impacting the normal operation of electronic equipment. Therefore, determining the CAN line trace width and layout is a priority during wiring. Trace widths are designed based on existing circuit board current-carrying capacity test results. Specifically, the circuit board current-carrying capacity test results show that in harsh environments, when the PCB copper foil thickness is 35μm, a trace width of 1.5mm can carry a long-term current of 1A. The required trace width is calculated based on the current required to be carried by each wiring harness loop. When the current is less than 1A, the trace width is designed to be 1.5mm. When the current is greater than 1A, the trace width is designed based on the formula: trace width (mm) = current (A) × 1.5.

[0035] like Figure 3The figure shows a schematic diagram of the shielding layer design around the CAN line. In the present invention, the CAN line 17 is a milliampere current and is routed using a 0.4mm line width with a large margin. When routing the CAN line 17, it is routed on the bottom layer 3 of the PCB board, following the routing principle of a line spacing greater than 3 times the line width (3W) and the shortest routing path principle. The center console PCB automotive wiring harness system 1 and the trunk PCB automotive wiring harness system 2, and the CAN line 17 are all routed on the bottom layer 3 of the PCB. The CAN line 17 is set separately on the bottom layer of the PCB for routing, and a shielding layer is designed on the second bottom layer to block interference from other high-current loops and protect the CAN line signal. The CAN line 17 is a key line for communication between control units in the automotive wiring harness. Its core function is to achieve the coordinated operation of each control unit through efficient data transmission. The center console PCB automotive wiring harness system 1 designs a GND shielding layer around the CAN line 17 and on the second bottom layer. The GND shielding layer can suppress internal crosstalk between multi-layer PCBs and improve the signal integrity of the CAN line. Conventional wiring harnesses are routed on layers 1-4, with the width of the wiring harness designed based on the required current carrying capacity. The gaps between the conventional wiring harnesses are filled with a GND shield layer, and through-holes 18 are placed on both sides of the CAN line 17 to connect the GND shield layers between different layers. Through-holes are placed on both sides of the CAN line to connect the GND shield layers between different layers, further protecting the signal integrity of the CAN line. Trunk PCB automotive wiring harness system 2 features a GND shield layer around CAN line 17 and on the sub-bottom layer, with conventional wiring harnesses routed on layers 1-2. Conventional wiring harnesses primarily include power lines and low-frequency switching signal lines, other than the CAN line. The width of the conventional wiring harnesses is designed based on the required current carrying capacity. The gaps between the conventional wiring harnesses are filled with a GND shield layer, and through-holes 18 are placed on both sides of the CAN line 17 to connect the GND shield layers between different layers.

[0036] The routing spacing between different groups of CAN lines 17 in the center console PCB automotive wiring harness system 1 and the trunk PCB automotive wiring harness system 2 is greater than three times the line width and can be appropriately widened based on the space margin. The line spacing can be widened to 10 times the line width or greater based on the size of the PCB board space. The line spacing between CAN lines in the same group is greater than three times the line width, that is, greater than 1.2mm. When the CAN lines follow the 3W routing principle, the electric field coupling between the lines can be greatly reduced, protecting their signal integrity. At the same time, the routing paths of the CAN lines 17 in the center console PCB automotive wiring harness system 1 and the trunk PCB automotive wiring harness system 2 follow the shortest routing path principle, which helps to reduce signal attenuation during transmission. In addition, the shorter routing path can effectively reduce the risk of electromagnetic interference and thus improve communication reliability. Compared with traditional automotive wiring harnesses, it can significantly improve signal integrity and anti-interference capabilities, which is of great significance for automotive functions with high signal requirements.

[0037] The present invention designs the PCB board based on the functional requirements and layout of the vehicle. By stacking the PCB in multiple layers (such as a 6-layer design for the center console PCB and a 4-layer design for the trunk PCB) and designing a shielding layer around the CAN line, the conventional wiring harness and the CAN line can be tightly fitted to the reference plane, thereby achieving the effect of optimizing the spatial stacking structure. Compared with traditional automotive wiring harnesses, a flat layout of the wiring harness path is achieved, the spatial stacking structure is optimized, and high-density integrated wiring is achieved. The PCB board weighs between 400g and 450g, which significantly reduces the weight of the entire vehicle compared to traditional automotive wiring harnesses. This feature is particularly suitable for scenarios with high requirements for lightweight vehicle chassis and space utilization.

[0038] During wiring, the 3W and shortest routing principles are adhered to, with the addition of a GND shielding layer to isolate electromagnetic interference and minimize signal transmission paths. The CAN line 17 of the present invention is routed only on the bottom layer of the PCB board. The CAN line width is 0.4 mm, and the spacing between different groups of CAN lines is greater than three times the line width. The routing paths between different connectors are minimized. Furthermore, a GND shielding layer is designed to isolate the CAN line from other circuits, ensuring stable signal transmission.

[0039] Step S3: Design a three-section PCB protection housing with a guide and hanging structure according to the size of the PCB board, the position of the connector, and the installation environment.

[0040] The size of the PCB affects the size of its protective housing, which in turn influences the size and cost of the injection mold for the protective housing, as well as the deformation of the product after cooling. For a given level of complexity, a larger protective housing requires a larger injection mold, which increases the cost and also increases the deformation of the molded product after cooling. The location of the connector determines the opening position of the protective housing. The bracket mounting location or the development of a matching bracket should be tailored to the installation environment.

[0041] After the PCB design is completed, the corresponding protective shell needs to be designed to fix the PCB on the car sheet metal. Since the PCB board is 714mm long and has a long size, in order to suppress the deformation of the protective shell during the injection molding process, a three-section spliced ​​PCB protective shell is adopted. The PCB protective shell is divided into three sections of upper shell 12 and three sections of lower shell 13. A guide hanging structure 11 is designed on the lower shell 13 to achieve rapid splicing between adjacent sections of the lower shell 13. The lower shell 13 can be used in both the center console PCB automobile wiring harness system 1 and the trunk PCB automobile wiring harness system 2, reducing mold costs. Figure 4 As shown, the guide and hook structure 11 includes a first locking structure 111 and a first guide rail 112. Figure 4As shown in (a), the first guide rail 112 is provided on both sides of one end of the lower shell 13, the first locking structure 11 is provided on the lower shell 13 between the two first guide rails 112, the first locking structures 111 are respectively provided at one end of the adjacent sections of the lower shell 13, the first locking structure 111 includes a positioning hole 114 and a first lock buckle 113, the positioning hole 114 is adapted to the first lock buckle 113, the end of the first lock buckle 113 is provided with a protrusion engaged with the positioning hole 114, the first lock buckle 113 is provided at one end of a section of the lower shell 13, the positioning hole 114 is provided at the other end of the adjacent section of the lower shell 13 to be spliced, so as to facilitate the engagement of the protrusion on the first lock buckle 113 with the positioning hole 114. A section of the first guide rail 112 is designed in front of the first locking structure 111 at the joint of the lower shell. When splicing, the lower shell 13 is pushed along the first guide rail 112 so that the positioning hole and the lock buckle can be quickly spliced, as shown in FIG. Figure 4 As shown in (b), the number of positioning holes and first lock buckles of each two sections of the lower shell 13 to be spliced ​​is 2, and they are evenly distributed on the lower shell 13 between the first guide rails.

[0042] The PCB protection housing is designed with a pre-installed guide structure 10 for pre-installing the upper housing 12 and the lower housing 13. The pre-installed guide structure 10 can realize the rapid positioning of the upper and lower housings and improve the assembly efficiency. Figure 5 As shown, the pre-installed guide structure 10 includes matching protrusions 101 and grooves 102. The protrusions 101 are provided on the upper shell 12, and the grooves 102 are provided on the lower shell 13 at corresponding positions. When the upper shell 12 and the lower shell 13 are assembled, the protrusions of the upper shell 12 and the grooves 102 of the lower shell 13 are aligned to achieve quick positioning of the upper shell 12 and the lower shell 13. The upper shell 12, the center console PCB 14 / the luggage compartment PCB 16 and the lower shell 13 can be fastened together using self-tapping screws 9, which is convenient and quick. At the same time, the PCB protective shell is equipped with a detachable mounting bracket 15, which can match different installation environments and fix the PCB protective shell to the body sheet metal, avoiding the risk of traditional wiring harnesses being easily loosened by mechanical pulling and vibration, and the failure caused by wiring harness breakage or poor contact. As shown Figure 6As shown, the upper portion is a mounting bracket 15 for the center console PCB automotive wiring harness system 1, and the lower portion is a mounting bracket 15 for the trunk PCB automotive wiring harness system 2. The mounting bracket 15 includes a fixing foot 153, which is fixed to the lower portion of a fixing plate. The fixing plate is used to connect the fixing foot 153 and the lower housing 13. A second locking structure 152 is provided between the fixing plate of the mounting bracket 15 and the lower housing 13 to facilitate disassembly. A second guide rail 151 is provided on the upper portion of the fixing plate, and a guide groove is provided on the lower housing 13 to match the second guide rail 151. The second guide rail 151 is slidably connected to the guide groove, allowing for assembly and disassembly of the mounting bracket 15 and the lower housing 13, while also facilitating the engagement of the second locking structure 152. The second locking structure 152 includes a mounting bracket 154 and a second locking catch 155. The second locking catch 155 is located on the upper portion of the fixing plate. The mounting bracket 154 is located on the lower portion of the lower housing 13. The mounting bracket 154 mates with the second locking catch 155. The end of the second locking catch 155 is provided with a protrusion that engages with the mounting bracket 154. Manually pulling the protrusion releases the connection between the mounting bracket 15 and the lower housing 13. The mounting bracket 15 is connected to the lower housing 13 via the second locking structure 152. Bolts secure one side of the fixing leg 153 to the vehicle body. Multiple guide slots can be designed in the lower housing 13 to support installation of the mounting bracket 15 at different locations within the lower housing 13, adapting to various installation environments.

[0043] The three-section PCB protective housing proposed in this invention features a guiding and mounting structure, facilitating installation, reducing mold costs, and suppressing deformation. The housing features a removable mounting bracket, adapting to various installation environments and enabling quick attachment to the vehicle body sheet metal. This eliminates the risks of traditional wiring harnesses being easily loosened by mechanical pullout and vibration, as well as failures caused by wiring harness breakage or poor contact. The present invention utilizes a segmented assembly process, enabling the independent production, testing, and shipping of each functional sub-board, significantly reducing the overall assembly difficulty of complex wiring harnesses.

[0044] The present invention has a segmented assembly process. Its PCB board making, component welding, protective shell assembly and other processes can all be carried out on an independent production line. Automated equipment can also be used for PCB board making, welding and testing during the assembly process, which can greatly reduce the overall difficulty of assembling complex automotive wiring harnesses.

[0045] Step S4: Install the center console PCB automotive wiring harness system and the trunk automotive wiring harness system on the actual vehicle and connect them through connectors and FFC (Flexible Flat Cable).

[0046] After installing the center console PCB wiring harness system 1 and the trunk PCB wiring harness system 2 to their corresponding vehicle body positions, they are connected via FFC 8. The wiring harnesses of vehicle functional modules such as the body intelligent control, doors, and amplifiers are plugged into the connectors on the center console PCB wiring harness system 1 and the trunk PCB wiring harness system 2 through corresponding connectors.

[0047] Example 2 A modular automotive wiring harness system based on high-density integrated wiring includes a center console PCB wiring harness system 1 and a trunk PCB wiring harness system 2, interconnected via FFCs 8 and expandable based on vehicle functions. The center console PCB wiring harness system 1 includes a center console PCB 14, while the trunk PCB wiring harness system 2 includes a trunk PCB 16. Connectors are provided on both the center console PCB 14 and the trunk PCB 16. Each PCB is housed within a PCB protective housing, which protects the center console PCB 14 and the trunk PCB 16. The center console PCB 14 and the trunk PCB 16 are connected via FFCs 8. The center console PCB 14 includes five sets of 30-wire connectors 4, six sets of 40-wire connectors 5, one set of 24-wire connectors 6, and two sets of FFC-specific 48-wire connectors 7. The trunk PCB 16 includes one set of 30-wire connectors 4, two sets of 40-wire connectors 5, and two sets of FFC-specific 48-wire connectors 7. The two sets of FFC dedicated 48-wire connectors 7 on the center console PCB 14 are connected to the two sets of FFC dedicated 48-wire connectors 7 on the trunk PCB 16 through two sets of FFCs 8 respectively, thereby achieving connectivity between the center console PCB 14 and the trunk PCB 16.

[0048] The center console PCB 14 utilizes a 6-layer design with a thickness of 1.6 mm. The trace width is designed based on the assumption that, in harsh environments, a 1.5 mm trace width with a copper foil thickness of 35 μm can carry 1 A of current. The CAN line is routed on the bottom 3 layers of the PCB, adhering to the 3W and shortest trace path principles. A GND shield layer is designed around the CAN and on layer 5. Conventional wiring harnesses are routed on layers 1-4. The gaps between these conventional harnesses are filled with GND shielding layers, and through-holes are placed to connect the shielding layers between different layers.

[0049] The luggage compartment PCB 16 utilizes a 4-layer design with a thickness of 1.6 mm. The trace width is designed based on the assumption that, in harsh environments, a 1.5 mm trace width with a copper foil thickness of 35 μm can carry a current of 1 A. The CAN line is routed on the bottom layer 3 of the PCB board, adhering to the 3W and shortest trace path principles. A GND shielding layer is designed around the CAN and on the third layer, and conventional wiring harnesses are routed on layers 1 and 2. The gaps between the conventional wiring harnesses are filled with a GND shielding layer, and vias 18 are placed to connect the GND shielding layers between different layers. Vias 18 are typically located on both sides of the CAN line 17 and in large areas of the GND shielding layer to connect the GND shielding layers between different layers.

[0050] The PCB protection shell includes at least two sections of upper shell 12 and lower shell 13. The upper shell 12 or the lower shell 13 are connected by a guide hanging structure 11. The upper shell 12 and the lower shell 13 are pre-assembled by a pre-installed guide structure 10. Two pre-installed guide structures are set between each section of the upper and lower shells to achieve rapid positioning of the upper shell 12 and the lower shell 13, thereby improving assembly efficiency. The guide hanging structure 11 is set at the connection between adjacent lower shells 13 to achieve rapid splicing of the lower shells 13. Figure 2 As shown, the PCB protective housing consists of a three-section upper housing 12 and a three-section lower housing 13. Since the total length of the PCB protective housing is 714 mm, a three-section design effectively reduces deformation during the injection molding process. A mold core-swappable design enables differentiated openings for the connectors on the protective housings for the center console PCB automotive wiring harness system 1 and the trunk PCB automotive wiring harness system 2. This reduces mold costs by requiring only one new mold for the wiring harness system protective housing.

[0051] The bottom layers of the center console PCB 14 and the trunk PCB 16 are provided with a CAN line 17, and a GND shielding layer is designed around the CAN line 17 and on the second bottom layer of the PCB board. The routing gaps of other layers of the PCB board are filled with the GND shielding layer, and each layer of the PCB board is provided with a through hole 18 connected to the GND shielding layer.

[0052] The other structures are the same as those in Example 1.

[0053] During the development and production of a vehicle, changes and adjustments to the wiring harness may be necessary. This invention offers excellent scalability: adding new features requires only modifying the PCB board design file and adding the corresponding circuits to the PCB, without requiring large-scale changes to the entire wiring harness. This scalability allows vehicles to better adapt to changes in market demand and technological development.

[0054] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A modular automotive wiring harness system based on high-density integrated wiring, characterized in that: The invention comprises a center console PCB automobile wiring harness system (1) and a luggage compartment PCB automobile wiring harness system (2), wherein the center console PCB automobile wiring harness system (1) comprises a center console PCB (14), and the luggage compartment PCB automobile wiring harness system (2) comprises a luggage compartment PCB (16), and connectors are provided on both the center console PCB (14) and the luggage compartment PCB (16), and the center console PCB (14) and the luggage compartment PCB (16) are respectively arranged in a PCB protective shell, and the center console PCB (14) and the luggage compartment PCB (16) are connected via an FFC (8).

2. The modular automotive wiring harness system based on high-density integrated wiring according to claim 1 is characterized in that: The PCB protection housing comprises at least two sections of an upper housing (12) and a lower housing (13); adjacent lower housings (13) are connected via a guide hanging structure (11); and the upper housing (12) and the lower housing (13) are quickly positioned and pre-assembled via a pre-installed guide structure (10).

3. The modular automotive wiring harness system based on high-density integrated wiring according to claim 1 or 2, characterized in that: The bottom layers of the center console PCB (14) and the luggage compartment PCB (16) are provided with a CAN line (17), a GND shielding layer is designed around the CAN line (17) and on the secondary bottom layer of the PCB, the wiring gaps of other layers of the PCB are filled with the GND shielding layer, and each layer of the PCB is provided with a through hole (18) connected to the GND shielding layer.

4. A design method for a modular automotive wiring harness system based on high-density integrated wiring, characterized in that: The steps are as follows: Step S1: Divide the chassis wiring harness system into a center console PCB wiring harness system and a trunk PCB wiring harness system according to the regional distribution and connection relationship of the wiring harness. Step S2: Based on the number of wiring harnesses required for the center console PCB automotive wiring harness system and the trunk PCB automotive wiring harness system, select the appropriate connector type, and design the number of PCB layers, trace width, and CAN line routing path to obtain the center console PCB and the trunk PCB respectively; Step S3: Designing a PCB protective housing based on the size, connector location, and installation environment of the center console PCB and the trunk PCB; Step S4: Install the PCB protective housing, the center console PCB, and the trunk PCB in the actual vehicle, and connect the center console PCB and the trunk PCB through a connector and FFC.

5. The design method of a modular automotive wiring harness system based on high-density integrated wiring according to claim 4, characterized in that: The center console PCB is equipped with five sets of 30-wire connectors, six sets of 40-wire connectors, one set of 24-wire connectors, and two sets of FFC-specific 48-wire connectors; the trunk PCB is equipped with one set of 30-wire connectors, two sets of 40-wire connectors, and two sets of FFC-specific 48-wire connectors. The connectors provide pluggable connections between a large number of electronic components and electronic control units in the car. The center console PCB adopts a 6-layer design and a PCB thickness of 1.6 mm; the trunk PCB 16 of the trunk PCB automobile wiring harness system 2 adopts a four-layer design and a PCB thickness of 1.6 mm.

6. The design method of a modular automotive wiring harness system based on high-density integrated wiring according to claim 4 or 5, characterized in that: Design the required trace width according to the current in the loop: when the current is less than 1A, the trace width is designed to be 1.5mm. When the current is greater than 1A, the trace width is designed based on the formula trace width (mm) = current (A) × 1.

5. The CAN line has a milliampere current and is routed using a 0.4mm line width with a large margin.

7. The design method of a modular automotive wiring harness system based on high-density integrated wiring according to claim 6, characterized in that: The CAN lines are routed on the bottom layer (3) of the PCB board, following the routing principle of line spacing greater than 3 times the line width and the shortest routing path principle; the routing spacing of different groups of CAN lines in the center console PCB automobile wiring harness system and the trunk PCB automobile wiring harness system is greater than 3 times the line width, and is appropriately widened according to the space margin; the line spacing between the same group of CAN lines is greater than 3 times the line width.

8. The design method of a modular automotive wiring harness system based on high-density integrated wiring according to claim 7, characterized in that: The center console PCB automotive wiring harness system is designed with a GND shielding layer around the CAN line and the sub-bottom layer; Conventional wiring harnesses are routed on layers 1 to 4, and the routing gaps between conventional wiring harnesses are filled with GND shielding layers, and through holes are placed on both sides of the CAN line to connect the GND shielding layers between different layers; the trunk PCB automotive wiring harness system (2) designs a GND shielding layer around the CAN line and on the second bottom layer, and conventional wiring harnesses are routed on layers 1 to 2, and the routing gaps between conventional wiring harnesses are filled with GND shielding layers, and through holes are placed on both sides of the CAN line to connect the GND shielding layers between different layers.

9. The design method of a modular automotive wiring harness system based on high-density integrated wiring according to any one of claims 4, 5, 7, and 8, characterized in that: The PCB protection housing is a three-section housing having a pre-installed guide structure and a guide hanging structure; The PCB protection shell comprises a three-section upper shell (12) and a three-section lower shell (13), and the connection between adjacent sections of the lower shell (13) is designed with a guide hanging structure (11) that is connected to each other; the upper shell (12) and the lower shell (13) are provided with a pre-installed guide structure (10) to achieve rapid positioning of the upper shell (12) and the lower shell (13); The upper housing (12), the center console PCB (14) or the luggage compartment PCB (16) and the lower housing (13) are fastened together from top to bottom; A detachable mounting bracket (15) is provided on the lower shell (13), and the mounting bracket (15) is connected to the vehicle body.

10. The design method of a modular automotive wiring harness system based on high-density integrated wiring according to claim 9, characterized in that: The center console PCB automobile wiring harness system connects and clocks in the relevant wiring harnesses in the front and middle areas of the automobile; the trunk PCB automobile wiring harness system connects and clocks in the relevant wiring harnesses in the rear of the automobile; the CAN line is a key line in the automobile wiring harness for communication between control units; the center console PCB automobile wiring harness system (1) and the trunk PCB automobile wiring harness system (2) are connected via an FFC connector; the connectors on the center console PCB automobile wiring harness system (1) and the trunk PCB automobile wiring harness system (2) are respectively connected to the wiring harnesses of the vehicle functional modules in a plug-in manner via corresponding connectors; The guide and hanging structure (11) comprises a first locking structure (111) and a first guide rail (112), wherein the first guide rail (112) is arranged on both sides of one end of a lower shell (13), and the first locking structure (111) is arranged on the lower shell (13) and in the middle of another adjacent section of the lower shell (13), and the first locking structure (111) is located between the first guide rails (112); The first locking structure (111) includes a positioning hole (113) and a lock buckle (114), the positioning hole (113) is adapted to the lock buckle (114), and the end of the lock buckle (114) is provided with a protrusion that engages with the positioning hole (113), the lock buckle (114) is arranged at one end of the lower shell (13), and the positioning hole (113) is arranged at the other end of the adjacent lower shell sections (13) to be spliced; The pre-installed guide structure (10) comprises a matching protrusion (101) and a groove (102), wherein the protrusion (101) is arranged on the upper shell (12), and the groove (102) is arranged on the lower shell (13) at a corresponding position; The mounting bracket (15) includes a fixing foot (153), and the fixing foot (153) is fixedly connected to the vehicle body; the fixing foot (153) is fixed to the lower part of the fixing plate, and a second locking structure (152) is provided between the fixing plate and the lower shell (13). The upper portion of the fixed plate is provided with a second guide rail (151), the lower shell (13) is provided with a guide groove, and the second guide rail (151) is slidably connected to the guide groove; the second locking structure (152) includes a hanging platform (154) and a second lock buckle (155); the upper portion of the fixed plate is provided with the second lock buckle (155), and the lower portion of the lower shell (13) is provided with a hanging platform (154); the hanging platform (154) is adapted to the second lock buckle (155); The end of the second lock buckle (155) is provided with a protrusion that is engaged with the hanging platform (154).

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