A vehicle low-voltage wire harness segmented intelligent fault-tolerant layout system and method based on temperature sensing fuse self-protection

Abstract

The application discloses a kind of based on temperature sensing fuse self-protection whole vehicle low-voltage wire harness segmented intelligent fault-tolerant layout system and method, it is related to automobile whole vehicle low-voltage wire harness system technical field.The application is according to the rule of region boundary, electrical limit, safety isolation triple to the modularization segmentation of whole vehicle low-voltage wire harness, each segmented wire harness integrates temperature measuring function and intelligent fuse protection module.System real-time acquisition each segmented wire harness temperature, current, by vehicle body controller to work condition determination;When abnormal, preferentially execute hierarchical load shedding operation, load shedding is invalid then separately cut off fault segmented wire harness, realize fault isolation, complete fault information storage record simultaneously.The application discards traditional centralized passive protection mode, can accurately identify wire harness hidden overheat hidden danger, avoid single point fault causes whole road power failure, delay wire harness aging, greatly improve the safety of whole vehicle low-voltage distribution system, power continuity and repair efficiency, adaptation various new energy vehicles use.

Description

Technical Field

[0001] This invention relates to the field of automotive low-voltage wiring harness system technology, and in particular to a segmented intelligent fault-tolerant layout system and method for automotive low-voltage wiring harness based on temperature-sensitive fuse self-protection. Background Technology

[0002] The low-voltage wiring harness system of new energy vehicles is the core carrier for the transmission of electronic and electrical signals and the power supply of low-voltage electrical equipment in the vehicle. It is widely used in the electrical layout areas such as the engine compartment, chassis, and cabin of passenger cars and commercial new energy vehicles.

[0003] The existing low-voltage wiring harness structure mainly consists of low-voltage copper core wires, insulation layers, binding tape, protective corrugated tubing, connectors, and a centralized fuse box and relay power distribution circuit. The vehicle's low-voltage wiring harness adopts a continuous series wiring method, unifying all low-voltage loads such as vehicle lights, air conditioning, entertainment, body control, and actuators to the positive terminal of the battery. Overload and short-circuit passive protection for the vehicle's low-voltage circuit is achieved by relying on fuses inside the vehicle's fuse box and main circuit relays.

[0004] The existing technology works as follows: the battery outputs low-voltage DC power, which is then distributed to various branch circuits via the main low-voltage wiring harness. A fixed-specification fuse limits the current threshold of the entire branch circuit. When the instantaneous current in the circuit is too high, the fuse blows, cutting off the circuit and protecting downstream electrical equipment. The wiring harness relies on external corrugated tubing and insulating rubber for physical protection, vehicle-mounted clips for wiring harness positioning, and vehicle grounding points for circuit grounding, thus ensuring a stable power supply to the vehicle's low-voltage electrical system.

[0005] However, the existing low-voltage wiring harness system has the following obvious defects in terms of structural layout, protection methods, and power distribution logic: First, the vehicle wiring harness layout is not well organized and has poor fault isolation capabilities: the vehicle's low-voltage wiring harness is bundled in series as a whole, and high-power loads and low-current signal harnesses are bundled together, and safety loads and comfort accessory harnesses are laid on the same line. This not only makes it easy for local loads to overheat, but also makes it very easy for a fault in one line to cause the entire branch to lose power.

[0006] Secondly, the centralized fuse protection structure leads to a single-point fault causing a complete power outage: Existing low-voltage power distribution structures use a centralized fuse box protection mode, with only a single fuse protection element installed on each distribution branch. Because the wiring harness is a series-connected structure, when a short circuit or overload fault occurs at any point in the harness, the fuse directly blows the entire circuit, making it impossible to isolate the faulty section individually. This results in a complete power outage and paralysis of all related electrical components in the vehicle, poor system fault tolerance, and seriously affects the comfort of passenger and vehicle safety. Alternatively, passive fuse structures can be installed on the wiring harness, lacking any active control capability; once blown, physical replacement is required.

[0007] Third, the wiring harness load cannot be intelligently adjusted, and long-term high load accelerates the aging of the wiring harness: The existing low-voltage wiring harness power distribution structure is a pure hardware connection structure and does not have the electrical linkage control logic of the whole vehicle. When the whole vehicle's high-power low-voltage loads (such as blowers, defrosting heaters, electric pumps, etc.) are working at the same time, the instantaneous current carrying capacity of the wiring harness increases significantly, and the wiring harness is in a high-load heating state for a long time. Summary of the Invention

[0008] The technical problem this invention aims to solve is as follows: To address at least one of the industry's technical bottlenecks caused by the prevalent centralized fuse distribution and series wiring architecture in existing vehicle low-voltage wiring harnesses, such as the inability to monitor localized temperature rises, predict hidden thermal hazards, complete power outages due to single-point faults, lack of fault-tolerant power supply capabilities, inability to intelligently reduce loads under high-load conditions, difficulty in fault location, and poor adaptability of zoned protection, this invention provides a segmented intelligent fault-tolerant layout system and method for vehicle low-voltage wiring harnesses based on temperature-sensitive fuse self-protection. This system reconstructs the distributed segmented topology of the vehicle low-voltage wiring harness, abandoning the traditional centralized power distribution protection mode. Through segmented parameter monitoring, local isolation, and load-reduction linkage protection, it achieves a technological upgrade for low-voltage wiring harnesses, moving from passive fault fuse to active thermal management, from complete power outage paralysis to segmented fault-tolerant operation, and from blind disassembly and investigation to precise location and maintenance. This fully adapts to the safety deployment requirements of low-voltage wiring harnesses under all operating conditions in both new energy and traditional fuel vehicles.

[0009] The technical solution adopted by this invention to solve its technical problem is: a segmented intelligent fault-tolerant layout system for low-voltage wiring harnesses in vehicles based on temperature-sensitive fuse self-protection, comprising: Segmented wiring harness: The low-voltage wiring harness of the vehicle is divided into several independent segments. The intelligent fuse protection module is integrated at both ends of each segmented wire harness, replacing the traditional centralized fuse structure, and is used to realize the on / off control of each segmented wire harness; A wire harness domain control acquisition module is used to acquire the temperature and current of each segmented wire harness in real time. The body controller is communicatively connected to the wiring harness domain control acquisition module and the intelligent fuse protection module. It is used to compare the acquired data of each segmented wiring harness with a preset threshold to determine the working status of each segmented wiring harness. When a fault (abnormal temperature rise, overload, or micro-short circuit) is detected in any segmented wiring harness, a command is sent to control the load on the corresponding segmented wiring harness to be reduced, or to control the corresponding intelligent fuse protection module to cut off the faulty segmented wiring harness, while maintaining normal power supply to the remaining segmented wiring harnesses to achieve fault-tolerant operation.

[0010] After the fault is cleared, the body controller can reset the load and on / off state of the segmented wiring harness.

[0011] This system forms a minimum fault isolation unit by combining each segmented wiring harness with an intelligent fuse protection module. Protection is deployed locally to each segmented wiring harness, isolating only the faulty segmented wiring harness while ensuring continuous power supply to non-faulty segments. This fundamentally solves the shortcomings of traditional single-point short circuits that cause total power outages and complete vehicle electrical system paralysis, significantly improving the vehicle's low-voltage power supply fault tolerance. Simultaneously, the body controller actively controls the load and continuity of the faulty segmented wiring harness, achieving tiered fault-tolerant protection. This ensures the safety of the segmented wiring harnesses while maximizing the uninterrupted operation of onboard equipment.

[0012] In one set of embodiments, the body controller is also used to, when it detects that the segmented wiring harness data exceeds a preset threshold, link the vehicle domain control unit (VCU) and the battery management system (BMS) to execute a tiered fault handling logic.

[0013] When the data collected by the segmented wiring harness exceeds the preset threshold, the stepped fault handling logic first executes a graded load reduction strategy to reduce the line load, dynamically shuts down the current unnecessary low-voltage high-power load, reduces the current carried by the corresponding segmented wiring harness, and suppresses the temperature rise and aging of the segmented wiring harness caused by continuous high load operation. If the data collected by the segmented wiring harness still exceeds the preset threshold after the load is reduced, a circuit breaker operation is performed to disconnect the corresponding faulty segmented wiring harness.

[0014] This system proactively reduces load and controls current before the segmented wiring harness heats up but triggers a fuse, preventing long-term high-temperature creep and accelerated insulation degradation, effectively extending service life, reducing the frequency of abnormal fuse blowouts, and lowering the risk of short circuits and fires later on. Through cross-system safety integration with the VCU and BMS, it shuts down non-critical high-power loads in abnormal operating conditions, while maintaining continuous power supply for safety functions such as braking and steering, without affecting the overall vehicle driving safety.

[0015] In some embodiments, distributed temperature sensing units are arranged on the segmented wire harness to collect temperature data of the corresponding segmented wire harness in real time and transmit the temperature data to the wire harness domain control acquisition module, thereby improving the accuracy of temperature monitoring.

[0016] In some embodiments, a fault storage and location unit is also included, which is communicatively connected to the body controller, for accurately recording fault information such as the location of the segmented wiring harness where the fault occurred, the fault type, and the time of occurrence.

[0017] Maintenance personnel can view the information stored in the fault storage and location unit through the vehicle terminal or external diagnostic tool, without having to disassemble a large area of ​​the wiring harness sheath for troubleshooting.

[0018] In some embodiments, the segmented harness is divided based on a triple rule of area boundaries, electrical limits, and safety isolation.

[0019] Regional boundary delineation facilitates differentiated protection; electrical limit segmentation can balance segmented current loads; safety isolation rules enable zoned wiring to achieve fault isolation.

[0020] A segmented intelligent fault-tolerant layout method for low-voltage wiring harnesses in vehicles based on temperature-sensitive fuse self-protection includes the following steps: S1: The harness domain control acquisition module collects the temperature and current data of each segmented harness in real time and uploads them to the vehicle body controller; S2: The body controller compares the collected data of each segmented wiring harness with a preset threshold in real time to determine the current working status of each segmented wiring harness. S3: When any of the segmented wiring harnesses detects abnormal temperature rise or overload, the body controller performs graded load reduction according to the preset priority in the tiered fault handling logic; If the data returns to normal after the graded load reduction is executed, the vehicle body controller will then release the graded load reduction. If the data still exceeds the preset threshold after the graded load reduction is implemented, the body controller controls the intelligent fuse protection module on the faulty section harness to cut off the faulty section harness while maintaining normal power supply to the remaining section harnesses to achieve fault-tolerant operation. S4: Record the location of the faulty segment harness, the fault type, and the time of occurrence to the fault storage and location unit.

[0021] This method employs a closed-loop management system of multi-parameter acquisition, threshold comparison, tiered handling, and fault archiving to accurately assess the operating conditions of wiring harnesses based on multi-dimensional data such as temperature and current. In case of anomalies, priority is given to tiered load reduction and voltage adjustment, and the load limit is lifted once the operating conditions are restored. If this is ineffective, the faulty segment of the wiring harness is isolated separately while ensuring power supply to the remaining lines. This reduces unnecessary power outages, improves the reliability of the vehicle's power supply capacity, controls temperature from the source to delay wiring harness aging, and enables rapid fault location and repair in conjunction with fault information archiving.

[0022] In some embodiments, the preset threshold in step S2 includes a temperature preset threshold and a current preset threshold.

[0023] When the temperature of any segmented wire harness exceeds the preset temperature threshold and / or the current exceeds the preset current threshold, it is determined that the segmented wire harness is abnormal, and step S3 is triggered to perform a protection action.

[0024] The beneficial effects of this invention are: 1. Achieve segmented isolation and fault-tolerant power supply for higher vehicle reliability: By configuring independent intelligent fuse protection modules for each segment of the wiring harness and combining them with the data acquisition function of the wiring harness domain control acquisition module, when a short circuit or overload fault occurs in a certain segment of the wiring harness, only the faulty segment is isolated, while the remaining low-voltage circuits can operate normally and operate with fault tolerance. Furthermore, the segmented wiring harness can be reused again after the fault is cleared, changing the control mode from passive to active.

[0025] 2. Based on load linkage, delay wiring harness aging and extend service life: This solution links VCU, BMS and body controller, and through a stepped fault handling logic, reduces the load and disconnects the faulty segment wiring harness in abnormal working conditions. The above dual-path control method can effectively alleviate and eliminate faults, and the effect is significantly different from the existing single-path control method.

[0026] 3. Precise fault location, significantly reducing repair time and maintenance costs: The addition of a segmented wiring harness fault storage and location unit can accurately pinpoint the time, type, and location of the faulty segmented wiring harness, eliminating the need for manual disassembly and wire stripping for troubleshooting. This significantly improves the efficiency of offline testing and after-sales maintenance, reducing repair time and costs. Attached Figure Description

[0027] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0028] Figure 1 This is a framework diagram of the layout system of the present invention.

[0029] Figure 2 This is a schematic diagram of the segmented wire harness structure of the present invention.

[0030] In the diagram: 1. Segmented wiring harness; 101. Copper core conductor; 102. Insulation coating layer; 103. Distributed temperature sensing unit; 104. Outer protective layer; 2. Intelligent fuse protection module; 3. Harness domain control acquisition module; 4. Body control unit; 5. Fault storage and location unit. Detailed Implementation

[0031] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0032] Example 1: like Figure 1 , Figure 2The diagram illustrates Embodiment 1 of the present invention, a segmented intelligent fault-tolerant layout system for low-voltage wiring harnesses in a vehicle based on temperature-sensitive fuse self-protection. The system includes segmented wiring harnesses 1, an intelligent fuse protection module 2, a wiring harness domain control acquisition module 3, and a body controller 4. The intelligent fuse protection module 2 is located at both ends of the segmented wiring harnesses 1 and is used to control the on / off state of the segmented wiring harnesses 1. Simultaneously, distributed temperature sensing units 103 are arranged on the segmented wiring harnesses 1 to collect temperature data of the corresponding segmented wiring harnesses 1 in real time and transmit the temperature data to the wiring harness domain control acquisition module 3. The intelligent fuse protection module 2 has a built-in current acquisition unit that collects current data of the segmented wiring harnesses 1 in real time and synchronously sends it to the wiring harness domain control acquisition module 3.

[0033] Both the intelligent fuse protection module 2 and the wiring harness domain control acquisition module 3 are connected to the body controller 4. After the wiring harness domain control acquisition module 3 collects the temperature data uploaded by the distributed temperature sensing unit 103 and the current data uploaded by the intelligent fuse protection module 2, it feeds them back to the body controller 4. The body controller 4 compares the data of each segment of wiring harness 1 fed back by the wiring harness domain control acquisition module 3 with the preset threshold, determines the working status of each segment of wiring harness 1, and completes the fault type identification. In this embodiment, three types of faults can be identified: 1. Abnormal temperature rise: The temperature collected by the distributed temperature sensing unit 103 is higher than the preset temperature threshold; 2. Overload: The current collected by the intelligent fuse protection module 2 continuously exceeds the current preset threshold (such as the rated current threshold). 3. Micro-short circuit: instantaneous current surge, current fluctuation exceeding the normal range; When any fault such as abnormal temperature rise, overload, or micro-short circuit is detected in any segment harness 1, the body controller 4 can send a command to control the intelligent fuse protection module 2 on the corresponding segment harness 1 to cut off the faulty segment harness 1, while maintaining normal power supply to the other segment harnesses 1 to achieve fault-tolerant operation; it can also send a command to control the associated load of the corresponding segment harness 1 to perform graded load reduction to reduce the load and temperature of the corresponding segment harness 1.

[0034] In this embodiment, the segmented wiring harness 1 is divided as follows: the low-voltage wiring harness of the whole vehicle is divided into segments (segmented wiring harness 1) based on the three rules of area boundary, electrical limit and safety isolation.

[0035] The regional boundary rules are as follows: the entire vehicle is first divided into three primary regions: engine compartment, chassis, and passenger compartment. Each region is then further subdivided into sub-segments based on its installation boundaries. The engine compartment power accessories, chassis wheel-side electronic controls, and passenger compartment door / instrument loads are naturally segmented according to their installation locations. Based on the regional boundary rules, segmented wiring harnesses are defined to facilitate matching corresponding independent segmented protection for different areas such as high temperature, water immersion, and normal temperature.

[0036] Electrical limit rules: The total rated current of a single segmented wiring harness 1 shall be ≤25A; high-power electrical appliances such as PTC and low-pressure oil pumps shall occupy a single segmented wiring harness 1; low-current signal loads with a total current <5A may be combined into the same segmented wiring harness 1; the length of a single segmented wiring harness 1 shall be controlled between 1.2m and 2.5m, and additional segment breakpoints shall be added for extra-long trunk lines. By limiting the segmented range through electrical parameters, the load on each segment can be made uniform, avoiding frequent abnormal heating due to overload in a single segment.

[0037] Safety isolation rules: Vehicle safety loads (brake, VCU, BMS power supply) and vehicle comfort loads are separated by independent segmented wiring harness 1, ensuring that faults do not affect each other; corresponding segmented wiring harness 1 is installed at the interface of the high-temperature and water-degradable compartment as an isolation point, which can be matched with differentiated protection structures later. Safety loads and comfort loads are isolated by segmented wiring harness 1, and an additional segmented wiring harness 1 is added at the interface of operating conditions as an isolation break point. This ensures that if a single segment experiences overheating or short-circuit faults, only its own circuit is cut off, without affecting critical electrical control circuits. This significantly improves the fault tolerance of the vehicle's low-voltage power supply and avoids the defect of power outage of the entire branch due to a single point of failure. It should be noted that the low-voltage wiring harness of the whole vehicle is divided into N segments as needed based on the triple rules of area boundaries, electrical limits, and safety isolation. It is not limited by uniform length or fixed number of segments, and can be adapted to the development of wiring harnesses for new models with different vehicle architectures and load arrangements. Each segment of the wiring harness 1 can be configured with different levels of outer protective layers, such as protective corrugated pipes and wear-resistant and flame-retardant coatings, according to the requirements of its area boundaries, electrical limits, and safety isolation rules. This achieves graded protection and solves the problem of poor environmental adaptability caused by the lack of targeted graded protection in existing wiring harnesses.

[0038] The process of dividing the segmented harness 1 is as follows: First, based on the regional boundary rules, the three primary regions of the engine compartment, chassis, and cockpit are divided. Then, secondary segments are refined according to the device installation boundaries and load layout locations. Based on the electrical limit rules, combined with the circuit rated current, load power, and harness length constraints, the segment boundaries are defined. High-power loads are divided into independent segments, while low-current loads are combined into segments as needed. Based on the safety isolation rules, the segment boundaries of safety loads and comfort loads are distinguished. Segment isolation nodes are added at the junction points of high-temperature and water-related working conditions. Ultimately, the electrical protection of each segmented harness 1 is made independent of each other. A single segment fault can be isolated and disconnected separately without interfering with the normal power supply of other segments.

[0039] In this embodiment, the cross-section of the segmented wiring harness 1, from the inside out, consists of a copper core conductor 101, an insulating sheath 102, a distributed temperature sensing unit 103, and an outer protective layer 104. The distributed temperature sensing units 103 are evenly spaced and attached to the outer surface of the insulating sheath 102 (3-5 temperature measurement points are arranged in a single segmented wiring harness 1, with a temperature measurement accuracy of ±0.5℃). The distributed temperature sensing units 103 are directly attached to the heat source to collect the surface temperature signal of the segmented wiring harness 1 in real time. All temperature and current data are uniformly connected to the wiring harness domain control acquisition module 3, which uploads the collected data to the body controller 4 in real time via the CAN bus. The intelligent fuse protection module 2 assembled at both ends of the segmented wiring harness 1 is electrically connected to both ends of the copper core wire 101. The intelligent fuse protection module 2 is connected in series at the end of the segmented wiring harness 1 to realize independent controlled protection of a single segmented wiring harness 1. Based on the electronically controlled on / off function, the intelligent fuse protection module 2 can receive instructions from the body controller 4 to actively complete the circuit on / off control and realize independent isolation of fault segments.

[0040] It should be noted that the distributed temperature sensing unit 103 (such as a distributed NTC temperature sensing unit) and the intelligent fuse protection module 2 (with closing function) can adopt existing technologies, and their specific structures will not be described in detail here.

[0041] In this embodiment, the body controller 4, in conjunction with the vehicle domain control unit (VCU) and battery management system (BMS), establishes a cross-system closed-loop communication to exchange data such as vehicle load and battery status in real time. The body controller 4 incorporates a tiered fault handling logic. When abnormal temperature rise or overload is detected in segmented wiring harness 1, the body controller 4 activates the tiered fault handling logic to perform graded load reduction according to preset priorities, dynamically shutting down currently unnecessary loads, i.e., comfort-related loads.

[0042] The tiered fault handling logic is as follows: This tiered protection system supports two working modes: sequential triggering of Level 1, Level 2, and Level 3, and direct skipping of levels when the limit is exceeded. Sequential triggering: If the temperature and current still exceed the preset threshold only slightly, the first level of load reduction is executed first; if the temperature and current still exceed the standard after load reduction, the second level of load reduction is executed; if the operating condition still exceeds the limit after the second level of treatment, the third level of segmented disconnection is finally triggered. Skip-level trigger: If segmented wiring harness 1 experiences severe overheating or high-current short circuit, and the collected data directly exceeds the first and second level preset thresholds, the body controller 4 can directly skip to execute the third level segment cut-off, quickly isolate the faulty segmented wiring harness 1, and avoid the risk of fire.

[0043] The detailed classification rules are as follows: Level 1: When the collected data exceeds the preset threshold corresponding to Level 1 (such as 60℃~70℃, 20A~25A), the body controller 4 will activate the Level 1 warning and shut down the corresponding comfort loads such as seat heating, defrosting, and wireless charging. Level 2: After the Level 1 load reduction is performed, if the collected data exceeds the preset threshold corresponding to Level 2 (such as 70℃~85℃, 25A~35A), Level 2 protection is activated. The body controller 4 links with the VCU and BMS to reduce the power of the high-power loads (comfort loads) corresponding to Level 2, such as the blower, cooling fan, and electric water pump. Level 3: After performing Level 2 load reduction, if the collected data exceeds the preset threshold corresponding to Level 3 (such as ≥85℃, ≥40A), Level 3 disconnection is initiated. The body controller 4 triggers the intelligent fuse protection module 2 on this section of the wiring harness 1 to disconnect, isolate the faulty section of the wiring harness 1, and retain power supply to safety loads (essential electrical appliances for driving).

[0044] When the temperature and / or current of segmented harness 1 reaches the corresponding preset threshold, the system performs a first-level warning, a second-level protection, and a third-level disconnection action. After the fault is cleared and the parameters (temperature and current) are restored to the safe range, the load is automatically restored in reverse order, realizing intelligent protection throughout the entire process of "monitoring - warning - load reduction - isolation - location - recovery".

[0045] Example 2: like Figure 1 As shown is Embodiment 2 of the present invention. Based on Embodiment 1, a segmented intelligent fault-tolerant layout system for low-voltage wiring harnesses of a vehicle based on temperature-sensitive fuse self-protection is provided. It also includes a fault storage and location unit 5, which is communicatively connected to the body controller 4. The fault storage and location unit 5 is only responsible for receiving fault information from the body controller 4, completing local storage of fault information, matching of segmented wiring harness 1 locations, and uploading and outputting fault information. The body controller 4 adopts a multi-dimensional hierarchical matching comprehensive fault judgment logic, which is different from the existing conventional single threshold judgment technology for vehicle wiring harnesses. This judgment logic divides the fault risk level through a three-level tiered threshold, distinguishes between transient and permanent faults by combining the duration and time-domain characteristics of the fault signal, and binds the fault information with the segmented wiring harness 1 number to complete the precise matching of fault locations, forming a differentiated handling mechanism for the entire process of "monitoring-early warning-load reduction-isolation-location-recovery".

[0046] The body controller 4 accurately distinguishes between two types of faults: transient and intermittent faults, and permanent faults; (1) Instantaneous faults: short-term self-recoverable faults such as local overheating warning of wiring harness, short-term overload current fluctuation, and instantaneous poor contact; (2) Permanent faults: continuous overheating of the harness, short circuit of the harness, aging of the insulation layer, short circuit of the harness to ground, hardware damage of the intelligent fuse protection module 2, failure of the distributed temperature sensing unit 103 to collect data, segmented open circuit, continuous poor contact of the harness and other hardware faults that cannot be recovered by themselves. The fault storage and location unit 5 is used to record fault information such as the unique ID location of the segmented harness 1 where the fault occurred, the fault type, and the time of the fault occurrence.

[0047] In this embodiment, the system assigns a unique ID address (location information, such as JN-ZX-01, DP-ZX-01, CZ-ZX-01) to each segment harness 1 to help achieve accurate fault location (location matching).

[0048] Fault information can be pushed to the vehicle's instrument panel, central control screen, and OBD diagnostic interface via the CAN bus, and can also be uploaded to the vehicle terminal and owner's APP via T-BOX.

[0049] Example 3: Based on Embodiments 1 and 2, a segmented intelligent fault-tolerant layout method for low-voltage wiring harnesses in vehicles based on temperature-sensitive fuse self-protection includes the following steps: S1, Data Collection: The harness domain control acquisition module 3 communicates with the intelligent fuse protection module 2 at both ends of each segment harness 1 and the distributed temperature sensing unit 103 on the segment harness 1; the distributed temperature sensing unit 103 collects the temperature of the corresponding segment harness 1; the intelligent fuse protection module 2 has a built-in current sampling circuit to collect the current of the segment harness 1; after the harness domain control acquisition module 3 summarizes the temperature and current data of a single segment harness 1, it uploads them to the body controller 4. The harness domain control acquisition module 3 is arranged in a centralized manner, and not each segmented harness 1 is installed independently. All segmented harnesses 1 in the same engine compartment / chassis / cabin area of ​​the vehicle share one harness domain control acquisition module 3 to collect signals.

[0050] S2, State determination: The body controller 4 compares the temperature and current data collected by each segment wiring harness 1 with the preset temperature and current thresholds in real time to determine the current working status of each segment wiring harness 1 and identify faults. The body controller 4 distinguishes between two types of faults based on the duration of the fault and the characteristics of data fluctuations: transient intermittent faults and permanent faults. Transient intermittent faults: temperature / current exceeds the limit for a short time, the operating condition can recover on its own, and there is no hardware damage. Permanent faults: temperature / current exceeds the limit continuously and alarms are repeatedly triggered, indicating that there is hardware damage to the segment wiring harness 1, the distributed temperature sensing unit 103, or the intelligent fuse protection module 2.

[0051] S3, graded protection, fault-tolerant operation: When any segmented wiring harness 1 detects abnormal temperature rise (temperature exceeds preset temperature threshold) and / or overload (current exceeds preset current threshold) and / or micro-short circuit (instantaneous current surge, current fluctuation exceeds normal range), the body controller 4 executes the step-by-step fault handling logic.

[0052] When the system executes sequentially from level one to level three, it first shuts down and reduces unnecessary loads, reduces the current carrying pressure of the wiring harness, and suppresses the aging of the wiring harness due to temperature rise. If abnormal temperature rise and / or overload are still displayed after the first two levels are executed, the body controller 4 will only issue a disconnect command to the intelligent fuse protection module 2 at both ends of the faulty segment wiring harness 1 to disconnect the faulty segment wiring harness 1 separately. The intelligent fuse protection module 2 corresponding to all other non-faulty segment wiring harness 1 will remain conductive, the power supply circuit will not be disturbed, and the other circuits will be kept powered normally to achieve fault-tolerant operation.

[0053] If segmented wiring harness 1 experiences severe overheating or high-current short circuit, and the collected data directly exceeds the first and second level preset thresholds, the body controller 4 in the system can directly skip to execute the third level segment cutoff, quickly isolate the faulty segmented wiring harness 1, and avoid the risk of fire.

[0054] If the fault is cleared and the temperature and current of the faulty segment harness 1 return to normal during the execution of the tiered fault handling logic, the tiered fault handling logic will be released and the load will be automatically restored in reverse order.

[0055] After the fault is cleared and the temperature and current of the faulty segment harness 1 return to safe values, power supply is restored using a tiered dual-mode approach: The fault type is identified and determined by the body controller 4 after the tiered fault handling logic is executed and the wiring harness temperature and current return to the safety threshold. The fault feature identification is completed twice: the first fault risk is initially identified during the execution of the tiered fault handling logic, and the second fault type is finally identified based on the signal duration characteristics after the wiring harness temperature and current return to the safety threshold. The results of the second final identification are cross-checked and matched one by one with the instantaneous and permanent fault classification standards pre-divided in step S2 above. (1) Instantaneous faults (instantaneous short circuit, short-term overheating and other self-healing faults, which belong to the instantaneous fault category mentioned above): After the fault cause is eliminated and the collected parameter data (temperature, current) falls back to a safe value, the body controller 4 has no abnormality after a steady-state verification of 3s to 10s, and automatically drives the intelligent fuse protection module 2 on the faulty section harness 1 to close and restore the power supply to the section harness 1. (2) Permanent faults such as wire harness insulation damage and wire hard damage (belonging to the category of permanent faults mentioned above): The body controller 4 performs power-off interlocking on the faulty section wire harness 1 and prohibits the automatic closing of the intelligent fuse protection module 2. After the maintenance personnel complete the inspection and replacement of the fault point, they can manually restore the power supply to the section wire harness 1 by issuing a closing command through the vehicle diagnostic instrument.

[0056] It should be noted that during the recovery operation, if segmented harness 1 has been disconnected, power supply must be restored first, and then the load must be restored in reverse order.

[0057] S4, Fault information retention: The body controller 4 records the location of the faulty segment harness 1, the fault type, and the time of occurrence to the fault storage and location unit 5, and can push maintenance prompts to the vehicle terminal to facilitate maintenance personnel to quickly locate the fault point.

[0058] Example 1: Overheat warning for engine compartment wiring harness section → graded load reduction (normal driving scenario) 1. Specific scenario: The vehicle is running normally, the ambient temperature in the engine compartment is high, the blower and cooling fan are working for a long time, and the temperature of the main wiring harness in the engine compartment rises slowly.

[0059] 2. Hardware and Specifications: Monitoring object: Segmented harness 1 (ID: JN-ZX-01) located in the main harness section of the engine room. Distributed temperature sensing unit 103: NTC 10kΩ, B value 3950, sampling period 1 second; Temperature thresholds: ≤60℃ normal; 60℃~70℃ Level 1 warning; 70℃~85℃ Level 2 protection; ≥85℃ Level 3 disconnection; Current threshold: ≤20A normal; 20A~25A Level 1 warning; 25A~35A Level 2 protection; ≥40A Short circuit Level 3 disconnect.

[0060] 3. Execution steps: (1) The distributed temperature sensing unit 103 collected the temperature of the cabin segmented wiring harness 1 at 68°C and the current at 23A, reaching the first-level warning.

[0061] (2) Temperature sensing signal → wiring harness domain control acquisition module 3 → CAN bus → body controller 4 (BCM).

[0062] (3) When the BCM determines that it is a Level 1 warning, it will perform Level 1 load reduction: only turn off the corresponding small comfort loads in the vehicle body at Level 1, such as seat heating, rear defrosting, exterior rearview mirror heating, wireless charging, and ambient lighting; no load reduction command will be sent to VCU and BMS during Level 1.

[0063] (4) After the primary load is shut down, the load on the harness decreases, the temperature of segment harness 1 drops to 58°C, and after 10 seconds, the system maintains its current steady state.

[0064] (5) If the temperature continues to rise to 82℃ after the first-level load reduction, it will officially enter the second-level protection phase: BCM sends a secondary load reduction request to VCU and BMS via the CAN bus: VCU: Limits the power output of high-power accessories such as air conditioner blowers and cooling fans (Level 2 comfort loads). BMS: Maintain 12V regulated output without reducing drive power (for safety-related loads). Simultaneously reduce or turn off the corresponding secondary loads such as air conditioning and entertainment systems, and only retain the driving safety loads.

[0065] (6) When the temperature reaches the preset threshold of 82℃ for the secondary temperature, the fault is determined to be a short-term over-temperature fault of the wiring harness under the instantaneous and occasional fault (belonging to the category of instantaneous and occasional faults mentioned above); the fault information (ID: JN-ZX-01, fault type: short-term over-temperature fault of wiring harness, temperature: 82℃, fault occurrence time) is stored in the fault storage and positioning unit 5 and pushed to the vehicle instrument panel, central control screen and OBD interface.

[0066] 4. Recovery conditions: Temperature ≤55℃, current ≤20A, duration 10 seconds, no faults, the system restores the load in reverse order step by step.

[0067] Example 2: Partial short circuit in chassis wiring harness section → segmented fuse isolation (water wading / bumpy driving scenarios) 1. Scenario: When the vehicle is driving on a bumpy or flooded road, the chassis wiring harness is worn and the insulation is damaged, resulting in a micro-short circuit to ground and a sudden increase in current.

[0068] 2. Hardware and Specifications: Monitoring object: Segmented harness 1 (ID: DP-ZX-01) located in the main harness section of the chassis. Intelligent fuse protection module 2: 12V eFuse, rated 25A, short circuit response ≤10μs; Short-circuit current preset threshold: ≥40A instantaneous disconnection.

[0069] 3. Execution steps: (1) When segmented harness 1 is short-circuited, the current instantly rises to 55A, and the distributed temperature sensing unit 103 (temperature sensor) synchronously detects the rapid rise in temperature.

[0070] (2) The harness domain control acquisition module 3 collects current and temperature data in real time and uploads them to the BCM.

[0071] (3) When the BCM determines the fault to be level three: the harness short circuit fault, the two sets of intelligent fuse protection modules 2 on the segment harness 1 are driven to perform the disconnection operation immediately to isolate the faulty segment harness 1. The disconnection action synchronously sends load control instructions to the VCU and BMS through the CAN bus. The disconnection and load reduction limit actions are executed synchronously and in parallel.

[0072] It should be noted that for first and second-level faults with slow temperature rise, a graded load reduction is strictly implemented according to the preset priority: in the first-level warning stage, comfort loads such as seat heating, defrosting, and wireless charging are shut down; when the parameters continue to deteriorate and reach the preset threshold of the second-level protection, the VCU and BMS are linked to reduce the output power of high-power loads such as blowers, cooling fans, and electric water pumps. However, there is a risk of spontaneous combustion of the wiring harness due to instantaneous high-current short circuits. Therefore, the graded load reduction process cannot be waited for, and the third-level disconnection scheme is directly implemented to isolate the faulty segment of the wiring harness and simultaneously complete the load management of the entire vehicle. A two-way (load reduction + disconnection) synchronous handling is adopted to doubly reduce the safety hazards caused by short circuits.

[0073] (4) The segmented wiring harness 1 of the engine compartment and cockpit section is kept powered normally, and safety loads such as instruments, lights, steering, and brakes are not affected, thus achieving fault-tolerant power supply.

[0074] (5) The BCM synchronously notifies the VCU and BMS via the CAN bus: VCU: Low voltage circuit fault warning. Maintain safe driving mode. BMS: Maintain a stable 12V output and prohibit high-power low-voltage output (for comfort loads).

[0075] (6) Fault information (ID: DP-ZX-01, fault type: harness short circuit fault (action: disconnection), time) is stored in the fault storage and location unit 5.

[0076] (7) Fault notification: The vehicle instrument panel illuminates the fault light, the central control displays "Chassis wiring harness fault, isolated", the T-BOX uploads to the APP, and the OBD outputs the accurate ID.

[0077] 4. Restoration conditions: After the wiring harness short circuit fault is eliminated, repaired and repositioned, the temperature ≤55℃ and the current is normal before manual restoration of conduction is allowed.

[0078] Example 3: Overload of cockpit wiring harness section → Active load reduction protection (power supply during parking / charging scenario) 1. Scenario: When the vehicle is parked and charging / the air conditioning is on, high-power loads in the cabin are turned on at the same time, causing segmented wiring harness 1 to overheat due to overload.

[0079] 2. Hardware and Specifications: Monitoring object: Segmented wiring harness 1 (ID: CZ-ZX-01) located in the main wiring harness section of the cockpit.

[0080] 3. Execution steps: (1) The temperature of the cabin segmented wiring harness 1 is 72℃ and the current is 28A. It first reaches the first-level preset threshold and performs first-level load reduction. After load reduction, the temperature and current still exceed the standard and enter the second-level protection zone.

[0081] (2) The collected data is uploaded to the BCM via the harness domain control acquisition module 3. The BCM determines that the cockpit segment harness 1 is overloaded.

[0082] (3) The BCM first completes the first-level load reduction: turning off seat heating, exterior rearview mirror heating, wireless charging and other first-level small comfort loads.

[0083] (4) Then execute the second-level load reduction: BCM sends linkage instructions to VCU and BMS.

[0084] VCU: Disable unnecessary low-voltage load startup (comfort loads); BMS: Reduces 12V charging current limit to prevent overcurrent in segmented harness 1.

[0085] (5) After the load is reduced, the temperature drops back to 62°C and the system maintains a safe state.

[0086] (6) The fault storage and location unit 5 records: ID, fault type, time, and pushes it to the vehicle terminal.

[0087] 4. Recovery conditions: Temperature ≤ 60℃, current ≤ 22A, duration 15 seconds, automatically restore safe load.

[0088] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A segmented intelligent fault-tolerant layout system for low-voltage wiring harnesses in vehicles based on temperature-sensitive fuse self-protection, characterized in that, Including the body controller (4), and The low-voltage wiring harness of the vehicle is divided into several groups of segmented wiring harnesses (1); each segmented wiring harness (1) is provided with an intelligent fuse protection module (2) that is actively scheduled to be switched on and off by the body controller (4) at both ends. The wiring harness domain control acquisition module (3) is connected to the body controller (4) for real-time acquisition of temperature and current data of each segmented wiring harness (1) and uploading it to the body controller (4). After identifying the fault, the body controller (4) actively cuts off the corresponding load of the segmented wiring harness (1) and the intelligent fuse protection module (2) to achieve fault-tolerant operation and resettable control after the fault is eliminated.

2. The intelligent fault-tolerant layout system for segmented low-voltage wiring harnesses in a vehicle based on temperature-sensitive fuse self-protection as described in claim 1, characterized in that, The segmented harness (1) is divided based on three rules: regional boundaries, electrical limits, and safety isolation.

3. The vehicle low-voltage wiring harness segmented intelligent fault-tolerant layout system based on temperature-sensitive fuse self-protection as described in claim 1, characterized in that, The body controller (4) has a built-in stepped fault handling logic; The tiered fault handling logic includes implementing graded load reduction on the faulty segmented harness (1) and cutting off the segmented harness (1), which can be performed sequentially or simultaneously.

4. The intelligent fault-tolerant layout system for segmented low-voltage wiring harnesses in a vehicle based on temperature-sensitive fuse self-protection as described in claim 3, characterized in that, The body controller (4) is linked with the vehicle domain control unit and battery management system to execute the stepped fault handling logic.

5. The vehicle low-voltage wiring harness segmented intelligent fault-tolerant layout system based on temperature-sensitive fuse self-protection as described in claim 1, characterized in that, The segmented wire harness (1) is provided with a distributed temperature sensing unit (103). The distributed temperature sensing unit (103) is communicatively connected to the harness domain control acquisition module (3).

6. The vehicle low-voltage wiring harness segmented intelligent fault-tolerant layout system based on temperature-sensitive fuse self-protection as described in claim 1, characterized in that, It also includes a fault storage location unit (5); The fault storage and location unit (5) is communicatively connected to the body controller (4) and is used to record fault information.

7. The vehicle low-voltage wiring harness segmented intelligent fault-tolerant layout system based on temperature-sensitive fuse self-protection as described in claim 1, characterized in that, The cross-section of the segmented wire harness (1) consists of, from the inside out, a copper core wire (101), an insulation layer (102), a distributed temperature sensing unit (103), and an outer protective layer (104). The outer protective layer (104) is configured with different levels according to the three rules of the segmented wire harness (1) area boundary, electrical limit and safety isolation.

8. A segmented intelligent fault-tolerant layout method for low-voltage wiring harnesses in a vehicle based on temperature-sensitive fuse self-protection according to any one of claims 1-7, characterized in that, Includes the following steps: S1: The harness domain control acquisition module (3) collects the temperature and current data of each segment harness (1) in real time and uploads them to the body controller (4). S2: The body controller (4) compares the collected data with the preset threshold in real time to determine the current working status of each segmented wiring harness (1); S3: When any segment of the wiring harness (1) experiences one or more of the following conditions: abnormal temperature rise, overload, or micro-short circuit, the body controller (4) performs graded load reduction according to the step-by-step fault handling logic to achieve load reduction. If the data returns to normal after the load reduction is implemented, the body controller (4) will release the tiered fault handling logic. If the data still exceeds the preset threshold after the load reduction is implemented, the body controller (4) controls the intelligent fuse protection module (2) on the faulty segment harness (1) to cut off, while maintaining the normal power supply of the remaining segment harnesses (1) to achieve fault-tolerant operation; S4: Record the location of the faulty segmented harness (1), the fault type and the time of occurrence to the fault storage and location unit (5).

9. The intelligent fault-tolerant layout method for segmented low-voltage wiring harnesses in a vehicle based on temperature-sensitive fuse self-protection as described in claim 8, characterized in that: In step S3, if the fault is cleared and the temperature and current of the fault segment harness (1) return to normal range during the execution of the step-by-step fault handling logic, the step-by-step fault handling logic is released and the load is restored in reverse order.

10. The method for segmented intelligent fault-tolerant layout of low-voltage wiring harness in a vehicle based on temperature-sensitive fuse self-protection as described in claim 8, characterized in that: In step S3, after the graded load reduction and the temperature and current of the faulty segment harness (1) return to normal, the body controller (4) identifies and determines the fault type; after the fault is eliminated, the power supply is restored in a graded dual-mode manner: (1) Instantaneous fault: After a set time period of steady-state verification, the body controller (4) automatically drives the intelligent fuse protection module (2) on the faulty segmented wiring harness (1) to close and restore power supply; (2) Permanent fault: The body controller (4) prevents the intelligent fuse protection module (2) on the segmented wiring harness (1) from closing, and manual recovery is required.

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