Axle-Routed Wire Harness Layout for Vehicle Wheel Swing Durability
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Solution Overview
Problem
The durability of the wire harness connecting vehicle body-side and wheel-side devices is compromised due to swinging and expansion/contraction when the vehicle body and wheel-side devices swing, leading to potential damage.
Innovation Solution
The wire harness is routed along the axle, torque rod, and cross member, with strategically placed connection points to absorb tensile and compression forces, and is optionally secured with binding bands or housed within these components to minimize swinging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional vehicle body structure is used, then manufacturing simplicity is maintained, but resistance to external impact forces and deformation is insufficient
Solution Approach 1:
The vehicle body is divided into modular components including front and rear impact absorbing members, side impact members, and a central cabin section. Each segment is independently designed to absorb specific types of impacts, allowing the structure to handle external forces more effectively while maintaining manufacturing simplicity through standardized modular units.
Solution Approach 2:
The body structure combines different materials with complementary properties - the impact absorbing members use energy-absorbing materials while the central cabin uses high-strength materials for protection. This composite approach enables the structure to resist external impact forces without requiring uniform complexity throughout the entire body.
2Strength
If the vehicle body is made more robust to prevent deformation, then protection against external forces improves, but the vehicle weight increases
Solution Approach 1:
Different regions of the vehicle body have different structural qualities optimized for their specific functions. The impact absorbing members are designed with collapsible structures that deform controllably, while the central cabin maintains rigid protection. This localized differentiation provides strong protection where needed without adding unnecessary weight throughout the entire vehicle.
Solution Approach 2:
The impact absorbing members are designed to change their structural parameters dynamically during impact events, transitioning from a rigid state during normal operation to a collapsible state during impact. This allows the structure to provide protection when needed while minimizing weight during normal vehicle operation.
3Reliability
If separate impact absorbing structures are added to the vehicle body, then resistance to external impacts improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The impact absorbing functions are merged into the primary body structure components themselves rather than being added as separate auxiliary systems. The front and rear impact absorbing members are integrated into the vehicle body framework, and the side impact members are incorporated into the door structures, simplifying manufacturing by reducing the number of separate parts and assembly steps.
Solution Approach 2:
The body structure components are designed to serve multiple functions - the front impact absorbing member not only absorbs frontal impacts but also contributes to the overall structural rigidity and crashworthiness of the vehicle. This multi-functionality reduces the need for separate dedicated components, thereby simplifying manufacturing while maintaining high reliability.
Data Source
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Figure 3(A)~3(B)
AI summary
[PROBLEMS] To improve the durability of an electric wire that connects units mounted on a vehicle. [SOLUTIONS] A vehicle includes a first unit on which a rotary electric machine is mounted, a second unit on which an inverter is mounted, an electric wire that electrically connects the first unit and the second unit, and a vehicle wheel that is dynamically connected downstream of the first unit via an axle, in which the electric wire has a portion routed along the axle.