Range extender control wire harness assembly

Abstract

The utility model relates to the technical field of automobile electronic appliances, specifically relates to a range extender control wire harness assembly, including wire harness main part, wire harness main part is made of the cluster of many conductors, set up in the central control interface of wire harness main part one end, and the function branch circuit that extends from the other end of wire harness main part, the end of function branch circuit is provided with the plug connector for connecting each executive component, function branch circuit includes power distribution branch, starting power generation branch and thermal management branch, the end of power distribution branch is connected with battery negative branch box connector, distribution box connector, battery control unit interface and whole vehicle controller interface, the end of starting power generation branch is connected with starter coil connector and generator interface, the end of thermal management branch is connected with preheating relay connector and electric control silicon oil fan connector, optimize the cabin space layout through the integrated wire harness design and the branch circuit of clear function, improve the assembly efficiency and the security of whole vehicle.

Description

Technical Field

[0001] This utility model relates to the field of automotive electronics and electrical technology, specifically to a range extender control harness assembly applied to a range extender system for new energy vehicles. Background Technology

[0002] The range extender is the core component of a range-extended electric vehicle (REEV), its main function being to provide electrical energy when the main battery is low on charge. A range extender system typically includes an engine, generator, and several key components such as electronic control units, vehicle controllers, and battery management systems. To achieve signal transmission and power distribution between these components, a dedicated low-voltage control harness is required for connection.

[0003] However, existing range extender wiring harnesses often have the following technical problems in practical applications: traditional range extender peripheral wiring harness designs are relatively dispersed, with the starter, preheating system, cooling fan, and various control units typically using separate wiring harnesses for segmented connections. This dispersed wiring harness design not only increases the number of assembly steps and connectors in the vehicle, but also leads to congested wiring space in the engine compartment, increasing the risk of interference and wear between the wiring harness and other moving parts. Summary of the Invention

[0004] The purpose of this utility model is to provide a range extender control wiring harness assembly to solve the technical problems of existing range extender peripheral wiring harness design being scattered, assembly process being complicated, engine compartment wiring space being crowded, and wiring harnesses being prone to interference and wear with other components. It aims to optimize engine compartment space layout, improve assembly efficiency and vehicle safety through integrated wiring harness design and clearly defined branch circuits.

[0005] To achieve the above objectives, this utility model proposes a range extender control harness assembly, comprising: The main body of the wire harness is composed of a bundle of multiple wires; A central control interface is located at one end of the main body of the wiring harness, and the central control interface is used to connect the range extender electronic control unit. And a functional branch circuit extending from the other end of the main body of the harness, wherein the end of the functional branch circuit is provided with a connector for connecting each actuator. The functional branch circuits include power distribution branch, start-up generation branch, and thermal management branch; The power distribution branch is connected to a battery negative junction box connector, a power distribution box connector, a battery control unit interface, and a vehicle controller interface at its end. The end of the starting power generation branch is connected to a starter coil connector and a generator interface; The end of the thermal management branch is connected to a preheating relay connector and an electronically controlled silicone oil fan connector.

[0006] Preferably, the main body of the wire harness is covered with a first protective layer, and the functional branch circuit is covered with a second protective layer.

[0007] Preferably, the first protective layer and the second protective layer are one or more combinations of corrugated pipe, PVC sleeve or wear-resistant tape.

[0008] Preferably, a wire branch fixing component is provided at the bifurcation point between the main body of the wire harness and the functional branch circuit. The wire branch fixing component is used to split and fix the wires, and the outside of the wire branch fixing component is wrapped with sealing tape.

[0009] Preferably, the main body of the wiring harness or the functional branch circuit is provided with several fixing buckles or cable ties at intervals to fix the wiring harness assembly to the vehicle body or the range extender body.

[0010] Preferably, the wires connecting the central control interface and the generator interface in the wiring harness body are shielded wires, which include a conductive core, an insulation layer, and a metal shielding layer.

[0011] Preferably, each connector of the functional branch circuit is marked with a label indicating the name or code of the corresponding connecting component.

[0012] Preferably, the connectors at the ends of the central control interface and the functional branch circuits are equipped with waterproof sealing rings, which are embedded in the mating surfaces of the connectors.

[0013] Compared with existing technologies, the range extender control wiring harness assembly provided by this utility model has the following substantial features and advancements: This range extender control wiring harness assembly changes the traditional distributed wiring method, adopting a highly integrated design concept. It bundles the wires for power distribution, start-up generation, and thermal management functions into the main body of the wiring harness, significantly reducing the number and volume of wiring harnesses around the range extender. This effectively solves the problem of congested wiring space in the engine compartment. Simultaneously, the orderly wiring harness routing avoids messy, suspended wiring, thereby greatly reducing the risk of interference, friction, or even damage between the wiring harness and vibrating or high-temperature components of the range extender, extending the service life of the wiring harness. Furthermore, by dividing the extended lines into power distribution branches, start-up generation branches, and thermal management branches, a clear modular layout is achieved. During vehicle assembly, operators can quickly locate the corresponding interface positions according to the functional branches, reducing misconnections or omissions caused by the complex wiring harness, significantly simplifying the assembly process and shortening operation time. In addition, during subsequent vehicle maintenance, the clear functional circuit division facilitates maintenance personnel in quickly diagnosing circuit faults, improving maintenance efficiency. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of a range extender control harness assembly in an embodiment of this utility model.

[0015] Reference numerals: 1. Wiring harness body; 2. Central control interface; 3. Power distribution branch; 4. Starter generator branch; 5. Thermal management branch; 31. Battery negative junction box connector; 32. Distribution box connector; 33. Battery control unit interface; 34. Vehicle controller interface; 41. Starter coil connector; 42. Generator interface; 51. Preheating relay connector; 52. Electronically controlled silicone oil fan connector. Detailed Implementation

[0016] The specific embodiments of this utility model will now be described in detail with reference to the accompanying drawings.

[0017] like Figure 1 As shown, a range extender control harness assembly includes: a harness body 1, which is composed of a bundle of multiple wires; a central control interface 2 disposed at one end of the harness body 1, which is used to connect to the range extender electronic control unit; and a functional branch circuit extending from the other end of the harness body 1, wherein the end of the functional branch circuit is provided with a connector for connecting various actuators.

[0018] The functional branch circuits include a power distribution branch 3, a starter generator branch 4, and a thermal management branch 5. The power distribution branch 3 is connected to a battery negative junction box connector 31, a power distribution box connector 32, a battery control unit interface 33, and a vehicle controller interface 34. The starter generator branch 4 is connected to a starter coil connector 41 and a generator interface 42. The thermal management branch 5 is connected to a preheating relay connector 51 and an electronically controlled silicone oil fan connector 52.

[0019] Specifically, the main body 1 of the wiring harness is composed of multiple wires of different specifications. The wires are selected based on their current carrying capacity and signal transmission sensitivity, using cables of different cross-sectional areas and shielding levels. To ensure the structural integrity of the wiring harness in the complex cabin environment, the main body 1 is not a haphazard collection of wires, but rather multiple wires are twisted together according to a predetermined layered structure using a specific cabling process to eliminate uneven stress caused by inconsistent wire lengths.

[0020] like Figure 1 As shown, one end of the wiring harness body 1 converges to the central control interface 2, which is the main physical port connecting to the range extender electronic control unit (ECU). The central control interface 2 typically uses a high-density multi-pin aviation plug or automotive-grade rectangular connector, integrating dozens or even hundreds of pin terminals. The terminals are connected to the wires in the wiring harness body 1 through a precise cold-pressing process, ensuring that control commands from the ECU can accurately enter the wiring harness system. At the same time, feedback signals from various sensors can also be fed into the ECU for processing through this interface.

[0021] Extending along the main body 1 of the harness to the other end, after reaching the predetermined physical node, the harness branches out into specific functional branch loops according to the different connected objects, abandoning the messy pattern of traditional point-to-point independent wiring, and grouping lines with similar directions and related functions into the same branch.

[0022] In this embodiment, the functional branch circuit is precisely divided into three core sections: power distribution branch 3, start-up and power generation branch 4, and thermal management branch 5. This not only conforms to the electrical logic of the range extender system but also closely matches the spatial layout of components in actual assembly.

[0023] like Figure 1 As shown, after the power distribution branch 3 branches off from the main body 1 of the wiring harness, it is further subdivided into four connection ports: battery negative junction box connector 31, power distribution box connector 32, battery control unit interface 33, and vehicle controller interface 34.

[0024] Specifically, the power distribution box connector 32 is responsible for introducing the vehicle's low-voltage power supply, which powers the range extender ECU and other actuators through the main power line inside the wiring harness. To meet the current requirements of different loads, the wires connecting the power distribution box connector 32 are usually selected from national standard or German standard automotive-grade wires with a larger cross-sectional area, such as AVSS or FLRY wires with a cross-sectional area of ​​2.5mm² or 4.0mm², to reduce line voltage drop.

[0025] The battery negative junction box connector 31 provides the system's reference ground potential (GND). Good grounding design is a prerequisite for ensuring accurate sensor signals and reliable actuator operation. Therefore, this branch usually uses braided copper tape or large-diameter wire to ensure low-impedance grounding.

[0026] In power distribution branch 3, in addition to pure power transmission, there is also a crucial communication line, namely the part connecting the battery control unit interface 33 and the vehicle controller interface 34. As the top-level control brain of the vehicle, the vehicle controller needs to send start / stop, power follow, and other commands to the range extender in real time; while the battery management system needs to coordinate the charging current and voltage with the range extender.

[0027] Therefore, the wiring connecting these two interfaces includes a high-speed CAN bus. In practice, to prevent the CAN signal from being affected by external electromagnetic interference, which could lead to packet loss or errors, this part of the wiring uses a twisted-pair structure, where two signal wires are twisted together with a specific pitch, using the common-mode rejection principle to cancel out external magnetic field interference.

[0028] The starter coil connector 41 and generator interface 42 are located at the end of the generator branch 4. In the operating logic of the range extender, the starter is responsible for driving the engine to ignition speed. Although this process is brief, the instantaneous current controlling the starter relay is large, accompanied by a strong inductive load back electromotive force. The wires connecting the starter coil connector 41 are typically connected in parallel with a freewheeling diode or transient suppression component in the wiring harness design.

[0029] Because generators produce high-frequency alternating current or pulsating direct current during operation, accompanied by strong electromagnetic radiation, improper handling can easily interfere with other weak electrical signals within the wiring harness. Therefore, this embodiment of the invention specifically emphasizes that the wires connecting the central control interface 2 and the generator interface 42 in the wiring harness body 1 are shielded wires.

[0030] The shielded conductor consists of, from the inside out, a conductive core, an insulation layer, a metal shielding layer, and an outer sheath. The metal shielding layer typically uses a tinned copper wire braided mesh with a braiding density of over 85%, or a fully wrapped structure using aluminum foil and Mylar tape. In actual connections, one end of the shielding layer is connected to the ECU housing via a dedicated grounding point at the central control interface 2, or grounded at the generator interface 42, creating a Faraday cage effect to guide high-frequency interference signals to the ground, thus ensuring that the vehicle's electromagnetic compatibility performance meets relevant standards.

[0031] Thermal management branch 5 is responsible for temperature control of the range extender system, ensuring the engine operates within its optimal thermal efficiency range. Its ends are connected to a preheating relay connector 51 and an electronically controlled silicone oil fan connector 52.

[0032] The preheating relay connector 51 is mainly used in diesel range extenders or intake air preheating systems in cold environments. Considering the high-temperature environment during the operation of the glow plug, the insulation layer of the wire in this branch is preferably made of high-temperature resistant materials such as cross-linked polyethylene or fluoroplastics, with a temperature resistance rating of 125℃ or even 150℃ or higher, to prevent the insulation layer from softening or cracking under long-term high-temperature baking.

[0033] The electronically controlled silicone oil fan connector 52 is used to transmit the PWM duty cycle signal. The ECU precisely controls the fan speed by changing the duty cycle of the PWM signal based on the data fed back by the engine coolant temperature sensor.

[0034] Because the fan is located behind the heatsink, airflow turbulence is significant and rainwater may intrude; therefore, this connector must have an extremely high waterproof and dustproof rating. In this embodiment, all connectors in the thermal management branch 5 are waterproof connectors with built-in silicone sealing rings, achieving a protection rating of IP67 or IP69K, ensuring that the internal circuitry remains dry and safe even under conditions of immersion in water or high-pressure water jet cleaning.

[0035] In addition to the aforementioned electrical connection logic, this invention also features meticulously optimized physical protection and manufacturing processes. The main body 1 of the wiring harness is covered with a first protective layer, while the functional branch circuits are covered with a second protective layer. In actual production, this protective layer is not made of a single material, but rather employs a combination of protective measures depending on the location.

[0036] For example, in high-temperature and high-vibration areas near the engine block and exhaust pipe, the first and second protective layers mainly use high-temperature resistant and flame-retardant corrugated tubing. The corrugated tubing's crest and trough structure not only gives the wiring harness good flexibility, making it easy to bend and lay wires in narrow spaces, but also provides excellent resistance to mechanical shock and wear.

[0037] For parts of the main body of the wiring harness that need to pass through sheet metal holes in the vehicle body or come into contact with sharp edges of the frame, the protective layer will be further strengthened. For example, an additional layer of wear-resistant cloth-based tape will be wrapped around the outside of the corrugated tube. This not only provides wear resistance but also has good noise reduction performance, effectively eliminating abnormal noises caused by collisions between the wiring harness and the vehicle body. In some terminal branches where flexibility is required but the risk of wear is low, PVC sleeves may be used to reduce weight and lower costs.

[0038] In handling the branching nodes of the wire harness, this embodiment of the invention employs an integrated branching fastener. Traditional wire harness branching is often achieved simply by wrapping with tape, which tends to loosen over time, leading to exposed wires. In contrast, the branching fastener in this embodiment is typically an injection-molded tee or multi-way connector, or a dedicated rubber molded component.

[0039] The main body of the wire harness and the branch are firmly snapped into or pass through the fixing member at the bifurcation point. Then, sealing tape is wrapped around the outside of the branch fixing member, which not only releases stress and prevents damage to the main connection when the branch is pulled, but also achieves sealing and waterproofing at the bifurcation point.

[0040] To further optimize assembly efficiency and ensure the reliability of wiring harness fixation, several fixing clips or cable ties are spaced apart on the main body or functional branch circuits of the wiring harness. The positions of the clips are determined based on the mounting holes of the range extender body and the vehicle body, after precise simulation analysis using a three-dimensional digital model.

[0041] The types of clips include various forms such as cedar-shaped cable ties, edge clips, and swivel clips. For example, when the wiring harness needs to have a certain amount of movement with slight engine vibrations, a swivel clip with a buffer structure is used; while in areas requiring absolute fixation, a rigid clip with a locating pin is used. This ensures that the wiring harness will not break due to being too tight, nor will it rub against and interfere with other components due to being too loose, throughout the entire lifespan of the vehicle.

[0042] In addition, to address the issue of production line workers having difficulty identifying and easily misconnecting components, each connector in the functional branch circuit is labeled with its corresponding name or code. These labels are typically made of oil-resistant and high-temperature-resistant PET material, printed using heat transfer technology, resulting in clear lettering that is resistant to fading and peeling even in harsh environments.

[0043] In response to the harsh operating environment of the range extender, this embodiment of the invention places particular emphasis on sealing design. The central control interface 2 and the connectors at the ends of the functional branch circuits are all equipped with waterproof sealing rings, which are embedded in the mating surfaces of the connectors. The sealing rings are typically made of silicone rubber or fluororubber, possessing excellent elastic memory and aging resistance. When the male and female connectors are properly inserted, the sealing rings are subjected to radial or axial compression, filling the tiny gaps between the housings and effectively preventing the intrusion of moisture, oil, and dust.

[0044] The range extender control harness assembly proposed in this embodiment highly integrates the dispersed electrical circuits such as power distribution, start-up power generation, and thermal management into a unified harness architecture. It uses shielded wires to solve electromagnetic interference, combined protective layers and dedicated fasteners to solve wear and fixation problems, and high-performance seals to solve environmental resistance problems. This not only reduces the assembly time of the range extender harness by more than 30% and significantly reduces the risk of incorrect or missing connectors, but also frees up valuable engine compartment space through optimized spatial layout and improves the flow of heat dissipation airflow, thereby significantly improving the reliability, safety, and production efficiency of the entire vehicle.

[0045] When implementing this utility model, technicians can flexibly adjust the length of each branch, connector type and wire specification according to the electrical architecture definition and range extender model of a specific vehicle, but its core integrated topology and protection concept should fall within the protection scope of this utility model.

[0046] This utility model is not limited to the specific technical solutions described in the above embodiments. Besides the above embodiments, this utility model may have other implementation methods. For those skilled in the art, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A range extender control harness assembly, characterized in that, include: The main body of the wire harness is composed of a bundle of multiple wires; A central control interface is located at one end of the main body of the wiring harness, and the central control interface is used to connect the range extender electronic control unit. And a functional branch circuit extending from the other end of the main body of the harness, wherein the end of the functional branch circuit is provided with a connector for connecting each actuator. The functional branch circuits include power distribution branch, start-up generation branch, and thermal management branch; The power distribution branch is connected to a battery negative junction box connector, a power distribution box connector, a battery control unit interface, and a vehicle controller interface at its end. The end of the starting power generation branch is connected to a starter coil connector and a generator interface; The end of the thermal management branch is connected to a preheating relay connector and an electronically controlled silicone oil fan connector.

2. The range extender control harness assembly according to claim 1, characterized in that, The main body of the wire harness is covered with a first protective layer, and the functional branch circuit is covered with a second protective layer.

3. The range extender control harness assembly according to claim 2, characterized in that, The first protective layer and the second protective layer are one or more combinations of corrugated pipe, PVC sleeve or wear-resistant tape.

4. The range extender control harness assembly according to claim 1, characterized in that, A wire branch fixing component is provided at the bifurcation point between the main body of the wire harness and the functional branch circuit. The wire branch fixing component is used to split and fix the wires. The outside of the wire branch fixing component is wrapped with sealing tape.

5. The range extender control harness assembly according to claim 1, characterized in that, The main body or functional branch circuit of the wiring harness is provided with several fixing buckles or cable ties at intervals for fixing the wiring harness assembly to the vehicle body or range extender body.

6. The range extender control harness assembly according to claim 1, characterized in that, The wires connecting the central control interface and the generator interface in the main body of the wiring harness are shielded wires, which include a conductive core, an insulation layer and a metal shielding layer.

7. The range extender control harness assembly according to claim 1, characterized in that, Each connector of the functional branch circuit is marked with a label near it, which is printed with the name or code of the corresponding connecting component.

8. The range extender control harness assembly according to claim 1, characterized in that, The central control interface and the connectors at the ends of the functional branch circuits are both equipped with waterproof sealing rings, which are embedded in the mating surfaces of the connectors.

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