Automated Bundle Diameter Calculation for Electrical Wire Harnesses
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Solution Overview
Problem
Designing and validating the wiring of complex electrical systems with multiple harnesses and terminal devices is challenging due to the difficulty in verifying the connection routes and safety of electrical wire bundles, particularly in determining the bundle diameter which affects routing and failure rates.
Innovation Solution
A device that calculates the bundle diameter of electrical wire bundles by associating electrical wires with connectors and relay elements through a storage unit and processing unit, allowing for easy counting and calculation of wire bundles based on connection information, enabling validation of wiring designs and accommodating design changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual checking of wiring diagrams is used to verify connection routes, then connection validity can be confirmed, but the process becomes extremely time-consuming and difficult when the system has large numbers of harnesses and terminal devices
Solution Approach 1:
The patent replaces manual mechanical checking of wiring diagrams with an automated computer-based calculation system. The calculating device automatically computes bundle diameters and verifies connection routes by processing wiring data, substituting human manual inspection with computational algorithms that rapidly analyze complex wiring systems.
Solution Approach 2:
The patent creates a digital representation (copy) of the physical wiring system through structured data files containing harness information, connector details, and wire specifications. This digital model allows automated calculation and verification without physically tracing or manually examining the actual wiring diagrams.
2Loss of information
If detailed wiring diagrams are used to show all connections, then complete connection information is available, but the diagrams spread over multiple sheets making it difficult to confirm safety and routing validity
Solution Approach 1:
The patent segments the complex wiring system into hierarchical data structures: individual wires, connectors, harnesses, and bundles are separated into distinct data entities. Each segment is stored with its specific properties in structured data files, allowing the system to manage complexity by breaking down the overall wiring diagram into manageable, searchable components.
Solution Approach 2:
The patent transitions from two-dimensional physical wiring diagrams spread across multiple sheets to a multi-dimensional data structure stored in computer files. The system organizes wiring information in hierarchical layers (wires within bundles, bundles within harnesses, harnesses within systems) that can be processed and analyzed in virtual space, eliminating the physical layout constraints.
3Manufacturing precision
If bundle diameter calculation is performed manually for each wire bundle, then accurate routing determination is possible, but the process becomes extremely time-consuming for complex wiring systems
Solution Approach 1:
The patent replaces manual measurement and calculation methods with automated computational algorithms. The calculating device automatically retrieves wire diameter specifications from stored data, computes bundle diameters using standardized formulas, and determines routing validity without manual intervention, maintaining precision while dramatically increasing calculation speed.
Solution Approach 2:
The patent performs preliminary organization of wire specifications, connector dimensions, and bundle configurations into structured data files before the actual calculation is needed. This pre-processing of data allows the calculation system to quickly retrieve and process information without manual data gathering, enabling rapid repeated calculations for design iterations.
Data Source
AI summary
A bundle diameter calculation device calculates the number of electrical wires belonging to an electrical wire bundle constituting a part of a wire harness of which each of the plurality of electrical wires is connected via relay points with connectors, the device including: a storage unit which stores electrical wire-connector connection information in which each of the plurality of electrical wires and the connectors are associated with each other, and bundle connection information which shows a state of connection with the connectors and relay elements by the unit of the electrical wire bundle of the wire harness; and a processing unit which, when the wire harness is specified, checks the electrical wire-connector connection information and the bundle connection information against each other and calculates the bundle diameter of the electrical wire bundle.