Automotive Wiring Backbone Architecture for Faster Assembly
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Solution Overview
Problem
Traditional automotive wiring systems are inefficient due to the extensive use of multiple, long, and flexible wiring harnesses that require manual assembly and lack optimization for power and signal transmission, leading to increased complexity and assembly time.
Innovation Solution
A new wiring architecture that reduces the number and length of cables by using a backbone system with subassemblies and umbilical cables, where controllers are integrated into subunits like door assemblies, and connectors are designed for efficient power and signal transmission, allowing for faster assembly and reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multiple wiring harnesses are used to connect each electrical component to a central battery, then each component can receive power and signals, but the total wire length becomes many miles and the system complexity increases significantly
Solution Approach 1:
The patent divides the traditional single centralized wiring system into multiple backbone segments distributed throughout the vehicle. Each backbone segment serves a specific region or function, reducing the need for long wire runs across the entire vehicle while maintaining reliable connections to all electrical components.
Solution Approach 2:
The patent introduces backbone segments as intermediary wiring structures between the central battery and electrical components. These backbones act as local distribution points, reducing the total wire length needed while ensuring reliable power and signal delivery to all components.
2Ease of operation
If flexible round conductors are used in traditional wiring harnesses, then the wiring can be easily routed, but the conductors are not optimal for transmitting current and require manual assembly which is slow
Solution Approach 1:
The patent changes the physical parameters of the conductors from flexible round shapes to rigid flat or rectangular shapes. This parameter change optimizes current transmission capability while the rigid structure allows for pre-assembly and automated installation, significantly improving assembly speed.
Solution Approach 2:
The rigid backbone structure allows wiring to be pre-assembled and configured before vehicle assembly. This preliminary action enables automated installation processes and reduces manual labor time during vehicle manufacturing, thereby increasing productivity.
3Adaptability or versatility
If multiple separate wiring harnesses are used for power, communication, and signals, then each function can be independently managed, but the total number of wires and assembly time increases
Solution Approach 1:
The patent merges power, communication, and signal functions into integrated backbone segments. Each backbone segment can handle multiple functions simultaneously through multi-conductor cables and integrated connectors, reducing the total number of separate wiring harnesses while maintaining functional independence through logical separation of signals.
Data Source
AI summary
A new wiring and power and communications system for an automobile that includes a plurality of devices, wherein the devices are connected to a backbone section that has an outer sheathing, a first conductor disposed within the outer sheathing, a second conductor disposed within the outer sheathing, a pair of inner sheathing members disposed within the outer sheathing and located on opposing sides of the at least one conductor, the inner sheathing members configured to electrically insulate the first conductor from the second conductor, and a shield member disposed within the outer sheathing.