Modular High-Voltage Cable Set Expansion Without Dummy Interfaces
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Solution Overview
Problem
Existing high-voltage cable harnesses in motor vehicles require significant installation space and incur costs due to unused interfaces, and there is a need for flexible expansion without dummy interfaces.
Innovation Solution
A cable set with a distribution box and an expansion unit that includes a housing with a power distribution unit and a fuse element, allowing for modular and scalable expansion by replacing conventional dummy interfaces, thus reducing installation space and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dummy interfaces are provided in the distribution box for potential future consumers, then adaptability is improved, but installation space and weight increase
Solution Approach 1:
The patent divides the distribution system into a main distribution box and separate expansion units. Each expansion unit is an independent module that can be added or removed as needed. This segmentation allows the main distribution box to remain compact without dummy interfaces, while expansion units provide the necessary adaptability when additional consumers are required.
Solution Approach 2:
The patent implements a dynamic configuration where the number and arrangement of interfaces are not fixed but can be adapted through modular expansion units. These units can be installed or removed based on actual requirements, making the system dynamically adjustable rather than statically over-provisioned with dummy interfaces.
2Adaptability or versatility
If dummy interfaces are provided in the distribution box for potential future consumers, then adaptability is improved, but weight increases
Solution Approach 1:
The distribution system is segmented into essential components in the main distribution box and optional components in separate expansion units. This eliminates unnecessary weight in the main unit while preserving adaptability through modular additions only when required.
Solution Approach 2:
The expansion units function as optional, add-on components that can be introduced only when needed. Rather than permanently carrying the weight of all possible interfaces, the system uses lightweight, on-demand expansion units that can be added or removed based on actual requirements.
3Manufacturing precision
If the cable set layout is fixed after the first development phase, then manufacturing precision is improved, but adaptability deteriorates
Solution Approach 1:
The cable set is segmented into a standardized main distribution box with fixed, precise routing and modular expansion units. The main unit maintains manufacturing precision with its finalized layout, while expansion units provide adaptability through standardized connection points that can accommodate additional consumers without requiring redesign of the entire cable set.
Solution Approach 2:
The expansion units are designed with universal connection capabilities that can accommodate different consumer types. The standardized interface design allows the same expansion unit to serve multiple functions and connect to various consumers, providing adaptability without compromising the precision of the main cable set layout.
4Adaptability or versatility
If conventional dummy interfaces are used in the distribution box, then adaptability is improved, but costs increase
Solution Approach 1:
The system segments the distribution functionality into a compact main unit and optional expansion units. This eliminates the cost of manufacturing and installing dummy interfaces in the main distribution box, while expansion units are only produced and installed when actually needed, reducing overall material and manufacturing costs.
Solution Approach 2:
Expansion units serve as economical, on-demand additions rather than permanent, expensive pre-provisioned dummy interfaces. They can be added only when required, avoiding the upfront cost of providing all possible interfaces in the main distribution box.
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The invention relates to a cable set (2), in particular a high-voltage cable set for a motor vehicle, with at least one supply conductor (10, 12) for supplying power to a consumer (8), with a distribution box (6) to which the at least one supply conductor (10, 12) is connected in the installed state.Furthermore, an extension unit (24) is provided, which has a housing (30) with an interior (32) in which a power distributor (48) is arranged, wherein the supply line (10, 12) is interrupted and has an end section (34) entering the interior (32) and an end section (36) exiting the interior (32), and the two end sections (34, 36) are electrically connected to the power distributor (48), wherein an additional line (20) for the electrical power supply of an additional consumer (18) is also provided, and the additional line (20) is connected to the power distributor (48) via an additional fuse element (26) located in the interior (32).