Hydraulic Manifold With Integrated Cables for Automated Assembly
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Solution Overview
Problem
The manufacture and assembly of wiring harnesses for connecting electrical components in coolant and refrigerant circuits of vehicles is laborious and costly due to their flexibility, requiring manual labor.
Innovation Solution
A hydraulic manifold that integrates electrical coolant and refrigerant circulation components and replaces separate wiring harnesses with integrated electrical cables, allowing automated assembly and connection to the vehicle's on-board power system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate wiring harness is used to connect electrical components, then the electrical connections can be established, but the manufacture and assembly become laborious and costly due to manual labor requirements
Solution Approach 1:
The patent combines the wiring harness functionality directly into the hydraulic manifold by integrating conductor strips into the manifold body. This merging eliminates the separate wiring harness and its manual assembly requirements, allowing automated manufacturing while maintaining reliable electrical connections between components and the vehicle's on-board power system
Solution Approach 2:
The hydraulic manifold is designed to serve multiple functions simultaneously: it distributes hydraulic coolant/refrigerant to various components and provides electrical connections through integrated conductor strips. This multi-functionality eliminates the need for separate wiring harnesses and reduces the number of assembly steps
2Reliability
If a separate wiring harness is used, then electrical components can be connected, but the overall device complexity increases and assembly becomes more difficult
Solution Approach 1:
The patent merges the electrical connection system with the hydraulic distribution system by integrating conductor strips into the manifold structure. This reduces device complexity by eliminating redundant components (separate wiring harness, connectors, mounting hardware) while maintaining all necessary electrical connections
3Ease of operation
If manual assembly is used for wiring harness installation, then flexible connections can be achieved, but manufacturing costs increase significantly
Solution Approach 1:
The integration of conductor strips into the hydraulic manifold allows the electrical connection system to be manufactured simultaneously with the manifold itself using automated processes. This eliminates the need for costly manual assembly of separate wiring harnesses while maintaining the necessary flexibility through the integrated design
Solution Approach 2:
The patent replaces the mechanical wiring harness assembly process with an integrated manufacturing process where conductor strips are embedded into the manifold during its fabrication. This substitution enables automated production and significantly reduces manufacturing costs
Data Source
AI summary
A hydraulic manifold (20) is configured to receive a plurality of electrical coolant and/or refrigerant circulation components (1a-3c) and to direct coolant/refrigerant to the components (1a-3c). The hydraulic manifold (20) includes a plurality of electrical cables (55) for connecting the plurality of electrical coolant and/or refrigerant circulation components (1a-3c) to an on-board power system of a vehicle.