EV Wire Harness Routing in Swing Arm Pivot
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Solution Overview
Problem
Conventional electric vehicle wire harnesses face interference and durability issues due to their rigidity, which impedes the swinging motion of the swing arm and can lead to contact with other components, compromising the vehicle's performance and reliability.
Innovation Solution
The electric vehicle design incorporates a wire harness that suspends from the frame, enters the pivot section, and is bent to reach the inverter through a partition-wall through port, allowing for flexible movement with the swing arm while being secured to prevent interference and enhance durability, using a seal and protection parts to prevent water ingress and foreign object contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a thick and stiff wire harness is used to supply large power to the electric motor, then power transmission capability is improved, but the wire harness interferes with the swinging motion of the swing arm and durability deteriorates
Solution Approach 1:
The wire harness is divided into multiple sections with different flexibility characteristics. The section within the swing arm uses a flexible conduit that can bend and follow the swinging motion, while the section outside uses a stiffer structure for power transmission. This segmentation allows each part to optimize its properties for its specific function and location.
Solution Approach 2:
A flexible conduit or sheath is used to enclose the wire harness within the swing arm, allowing it to bend and flex as the swing arm moves. This flexible enclosure protects the wires while accommodating the swinging motion, preventing damage from repeated bending and contact with other components.
2Reliability
If a stiff wire harness is used for power transmission, then electrical connection reliability is improved, but the wire harness contacts other components during swing arm motion and durability worsens
Solution Approach 1:
The wire harness routing is designed to be dynamic rather than fixed, allowing it to adapt its position as the swing arm moves. The flexible conduit within the swing arm enables the wire harness to follow the changing geometry during swinging motion, maintaining clearance from other components while preserving electrical connections.
Solution Approach 2:
The wire harness is nested within the hollow swing arm structure and protected by a flexible conduit, creating a nested arrangement that shields the electrical connections from external contact with other vehicle components while allowing the outer structure to move freely.
3Ease of manufacture
If the wire harness is routed directly between the body frame and swing arm, then installation simplicity is improved, but the wire harness cannot follow the swinging motion and durability deteriorates
Solution Approach 1:
The wire harness routing moves from a direct linear path to a three-dimensional path that follows the contours of the swing arm and accommodates its swinging motion. By utilizing the vertical and lateral dimensions within the swing arm structure, the wire harness can bend and flex naturally during motion while maintaining organized routing.
Data Source
AI summary
An electric vehicle includes a wire harness that flexibly follows the swinging of the swing arm, surely avoids any contact with other components, and has excellent durability. The electric vehicle includes a battery mounted to a frame, an inverter and an electric motor accommodated in a swing arm, and a wire harness wired between the frame and the swing arm. The swing arm includes a hollow pivot section, and a partition wall partitioning the pivot section and an arm section. The wire harness suspends from the frame side, enters inside the pivot section from the top face side of the pivot section, and is bent inside the pivot section reaching the inverter through the partition-wall through port.