Adjustable Wire Harness Using Nested Conductors for Length Variation
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Solution Overview
Problem
Conventional wire harnesses for drive motor-attached vehicles, such as hybrid and electric vehicles, face challenges in adjusting the length of single core wires to accommodate varying positions and distances between components like the inverter, high-pressure battery, and drive motor, making it difficult to use a single length for different vehicle types.
Innovation Solution
A wire harness configuration featuring a cylindrical conductor connected to a flexible conductor and a tubular conductor, where the cylindrical conductor can be adjusted in length by changing its insertion depth into the tubular conductor, allowing for easy length adjustment while minimizing the number of parts and improving connection flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single core wire is used for linear arrangement, then the wire harness can be simply arranged, but it is difficult to adjust the length to accommodate different vehicle types and component positions
Solution Approach 1:
The wire harness is divided into a flexible conductor portion and a cylindrical conductor portion that can be independently adjusted. The cylindrical conductor can be inserted to different depths into the tubular conductor, creating segmented adjustable sections that allow length customization without complicating the overall structure.
Solution Approach 2:
The wire harness incorporates a dynamic length adjustment mechanism where the cylindrical conductor can be inserted to variable depths into the tubular conductor. This dynamic configuration allows the wire harness length to be adapted to different vehicle types and component positions while maintaining structural integrity.
2Adaptability or versatility
If dedicated single core wires with different lengths are used for respective vehicle types, then the wire harness can fit different vehicle configurations, but it increases the number of parts and complexity
Solution Approach 1:
A single wire harness design with a cylindrical conductor and tubular conductor configuration serves multiple vehicle types and configurations. By adjusting the insertion depth of the cylindrical conductor into the tubular conductor, the same wire harness structure can accommodate different distances between inverter, battery, and motor across various vehicle models, eliminating the need for multiple dedicated wire harness variants.
3Ease of operation
If the cylindrical conductor is fitted into the tubular conductor with adjustable insertion depth, then the length of the wire harness can be adjusted with ease, but it may increase the number of parts
Solution Approach 1:
The cylindrical conductor is nested within the tubular conductor, with the cylindrical conductor inserted into the tubular conductor to the desired depth. This nesting configuration allows for easy length adjustment by varying the insertion depth while maintaining a compact structure. The cylindrical conductor can be secured at different positions within the tubular conductor to achieve the required length for different applications.
Data Source
AI summary
A wire harness that can be arranged in a vehicle, the wire harness including: a cylindrical conductor whose first end is electrically connected to a first flexible conductor that is flexible; and a tubular conductor that is electrically connected to the cylindrical conductor in a state in which a second end of the cylindrical conductor is fitted into an opening at a first end of the tubular conductor.