Deployable Wiring Harness Lattice for Automated Vehicle Routing

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Solution Overview

Problem

Vehicle wiring harnesses require a tedious and complex process of unfolding, flipping, and routing to target positions, leading to increased assembly time, potential damage, and assembly errors.

Innovation Solution

A deployable wiring harness system with insulated conductive cables arranged as a lattice, featuring bendable nodes, extenders, and stiffening members, allowing for automated deployment onto a vehicle chassis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a traditional wire bundle is used, then the wiring harness can be provided in a compact form, but it requires a long and tedious process of identifying sections, unfolding, flipping, and pulling to achieve target positions

Engineering Contradiction:

Improveease of deploymentVSAvoidassembly time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The wiring harness is divided into multiple lattice segments that can be independently manipulated and deployed. Each segment contains conductive cables arranged in a modular lattice structure with bendable nodes, allowing the harness to be unfolded and routed to target positions in a systematic manner rather than as a single complex bundle

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lattice structure incorporates bendable nodes that allow dynamic adjustment of the harness configuration during deployment. The extender mechanism provides dynamic force to urge segments toward their deployed positions, enabling the harness to adapt its shape as it is being installed rather than requiring manual manipulation of a static bundle

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If a traditional wire bundle is used, then the wiring harness can be provided in a compact form, but it requires complex interpretation of position and tedious yanking, unfolding, and flipping tasks

Engineering Contradiction:

Improveease of routingVSAvoiddeployment process complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manual mechanical process of yanking, unfolding, and flipping wire bundles is replaced with an automated deployment system that uses extenders and robotic manipulation. The extender mechanism automatically urges segments toward their deployed positions, eliminating the need for manual interpretation and manipulation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a traditional wire bundle is used, then the wiring harness can be provided in a compact form, but it may result in damage to the wiring harness requiring rework

Engineering Contradiction:

Improvewiring harness integrityVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The lattice structure provides inherent mechanical protection for the conductive cables within each segment. The rigid or flexible lattice framework cushions and protects the cables during handling and deployment, preventing damage before it occurs rather than requiring rework after damage happens

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The extender mechanism provides controlled dynamic force to deploy segments to their target positions without excessive stress. The bendable nodes allow the lattice to flex and adapt during deployment, preventing cable damage from sharp bends or excessive tension while maintaining deployment speed

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Reduces assembly time and minimizes errors by facilitating efficient, automated deployment of wiring harnesses onto vehicle chassis.

Implementation Method 1

a collapsible spring device defining the pivot point

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS20250353559A1System and method for a deployable wiring harness

Publication Date: 2025.11.20 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A deployable wiring harness system has a deployable wiring harness that includes insulated conductive cables with connectors assembled onto distal ends thereof. The insulated conductive cables are arranged as a lattice having segments joined at bendable nodes, wherein the segments are joined at the bendable nodes, and wherein the segments includes a machine-readable identifier. Also included is a wiring harness hanger that is affixed to one of the segments, and a wiring harness extender that is coupled to adjoined ones of the segments that are joined at the one of the bendable nodes. The wiring harness extender is arrangeable to urge the adjoined ones of the segments that are joined at the one of the bendable nodes towards a deployed state. An elongated stiffening member is affixed to respective insulated conductive cables of one of the segments at multiple locations.