Digital Harness Analog Sensor Interface Weight Reduction
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Solution Overview
Problem
Current electrical harnesses in vehicles are excessively heavy due to the use of analog data transmission and ruggedization, which contradicts weight reduction goals, especially in applications like aircraft, and fiber optic solutions are fragile and unsuitable for dirty environments.
Innovation Solution
A digital data harness using signal-specific conditioning circuits to convert analog signals to digital for transmission over fewer wires, with hermetically sealed digital interconnects and converters to prevent contamination, and the option to replace converters for compatibility and upgradeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If analog data transmission is used with dedicated wires for each component, then signal compatibility and simplicity are maintained, but the harness weight increases excessively
Solution Approach 1:
The patent replaces the mechanical/electrical analog signal transmission system with a digital communication system. Instead of using dedicated copper wires for each analog signal, the invention uses a microcontroller to generate digital communication signals that can carry multiple data streams simultaneously, thereby reducing the number of wires and overall harness weight while maintaining signal compatibility through digital-to-analog conversion at the receiving end
Solution Approach 2:
The patent implements a universal digital communication bus that can carry multiple types of sensor data simultaneously. The microcontroller-based system can handle various sensor inputs (temperature, pressure, flow, etc.) through a single communication channel, replacing the need for dedicated wires for each sensor type, thus achieving multi-functionality and weight reduction
2Weight of moving object
If fiber optic cables are used to reduce weight, then harness weight decreases, but the system becomes fragile and susceptible to contamination
Solution Approach 1:
The patent replaces the fragile fiber optic system with a robust electrical digital communication system using copper wires and microcontrollers. This substitution maintains the weight reduction benefit while improving reliability in dirty environments, as electrical connections are more tolerant of contamination and mechanical stress compared to fiber optic connections
Solution Approach 2:
The patent changes the signal transmission parameter from optical to electrical domain. By using electrical digital signals instead of optical signals, the system becomes more suitable for automotive environments where contamination and mechanical stress are common, while still achieving weight reduction through reduced wire count
3Weight of moving object
If digital communication is implemented without signal conversion, then wire count and weight are reduced, but compatibility with analog sensors is lost
Solution Approach 1:
The patent introduces microcontrollers and signal conversion circuits as intermediary devices between the digital communication bus and analog sensors. These intermediaries perform digital-to-analog conversion at the sensor end and analog-to-digital conversion at the controller end, enabling compatibility between digital communication infrastructure and analog sensors while maintaining weight reduction benefits
4Reliability
If ruggedization materials are added to protect the harness, then environmental resistance improves, but harness weight increases
Solution Approach 1:
The patent replaces the need for excessive ruggedization by implementing a fundamentally more robust digital communication system. The microcontroller-based digital signals are inherently more resistant to electrical interference and environmental factors compared to analog signals, reducing the need for additional protective materials and associated weight
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
The solution significantly reduces the number of wires and weight of the harness, maintains compatibility with a wide range of sensors, and prevents environmental contamination, achieving a lightweight and rugged digital communication system suitable for vehicle environments.
Implementation Method 1
a digital to analog/analog to digital (DA/AD) signal converter terminating at least one digital communication wire
Data Source
Figure 1~3
AI summary
A digital data harness, uses a signal specific conditioning circuit to interface with analog sensors. The signal specific conditioning circuits convert data signals from analog to digital and thereby allow the signals to be transmitted over a digital data harness.