Flat Wire Harness With Integrated Voltage Converters
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Solution Overview
Problem
Existing vehicle power distribution systems face challenges in accommodating both higher and lower voltage loads, as they near practical limits, requiring a system that can efficiently handle varying voltage levels while minimizing space and manufacturing costs.
Innovation Solution
A flat wire harness system with integrated voltage converters in each wire branch, allowing the system to provide specific rated voltages to electrical loads, using a high voltage power source to power both high and low voltage loads, and incorporating solid-state power switches and intelligent circuitry for fault protection and voltage conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a higher voltage system (48V) is implemented to meet increasing power demands, then power delivery capability is improved, but compatibility with existing lower voltage loads is lost
Solution Approach 1:
The patent implements local voltage conversion by integrating voltage converters directly into individual wire branches at the load level. This allows each branch to provide the appropriate voltage (12V or 48V) locally while the main system operates at 48V, enabling both high power delivery and voltage compatibility simultaneously
Solution Approach 2:
The power distribution system is segmented into multiple independent wire branches, each with its own integrated voltage converter. This segmentation allows different parts of the system to operate at different voltages independently, resolving the contradiction between high voltage power delivery and low voltage compatibility
2Ease of manufacture
If traditional round wire harnesses are used for power distribution, then ease of manufacture is maintained, but power loss increases and space efficiency decreases
Solution Approach 1:
The patent transitions from traditional round wire harnesses to a flat wire harness structure. This dimensional change improves space utilization and reduces power loss while maintaining manufacturing feasibility through standardized production processes for flat cables
3Device complexity
If voltage converters are placed centrally rather than integrated into wire branches, then device complexity is reduced, but power loss increases and adaptability decreases
Solution Approach 1:
Instead of a single centralized voltage conversion system, the patent segments voltage conversion functionality into multiple distributed converters integrated into individual wire branches. This reduces power loss by converting voltage closer to loads and improves adaptability while managing complexity through modular design
4Adaptability or versatility
If more wire branches and voltage converters are added to accommodate diverse voltage loads, then adaptability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The flat wire harness is designed as a universal platform that can accommodate multiple voltage loads through integrated voltage converters. The modular structure allows the same basic harness architecture to serve both 12V and 48V loads, reducing overall complexity despite the diversity of supported loads
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
This solution reduces power loss, optimizes wiring, and provides flexibility by placing voltage converters near loads, allowing for tailored voltage conversion, accommodating higher voltage loads while supporting legacy systems, thus enhancing system efficiency and reducing physical space and weight.
Implementation Method 1
a plurality of voltage converters, each integrated into a respective wire branch, configured to provide the respective rated voltage to each electrical load
Data Source
AI summary
Systems devices and methods are disclosed for a vehicle power distribution system having a flat wire harness with integrated voltage converters. An example power distribution system includes a battery having a nominal voltage, a plurality of electrical loads, each corresponding to a respective rated voltage, and a flat wire harness. The flat wire harness includes a plurality of wire branches, each configured to couple the battery to a respective electrical load. The flat wire harness also includes a plurality of voltage converters, each integrated into a respective wire branch, configured to provide the respective rated voltage to each electrical load.