Inline High-Voltage Wire Harness Disconnect for Modular EV Repair
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Solution Overview
Problem
Existing high voltage electrical systems in vehicles face challenges in efficiently removing and replacing wire harnesses, particularly due to space constraints and the need to remove other components, leading to costly and time-consuming repairs.
Innovation Solution
The implementation of an inline disconnect system that allows for the separation of high voltage wires within the wire harness, enabling selective disconnection and replacement of components without removing the entire harness, thereby reducing the length of wires that need to be removed and allowing for modular assembly and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire wire harness is removed for component replacement, then the component can be accessed and replaced, but the repair time and cost increase significantly
Solution Approach 1:
The wire harness is segmented into modular sections with disconnectors positioned at strategic locations. This allows the harness to be divided into separate replaceable units, enabling technicians to work on specific segments rather than removing the entire harness. The disconnectors create natural separation points that facilitate localized repair operations.
Solution Approach 2:
The disconnector components are extracted as separate removable elements from the wire harness assembly. These disconnectors can be independently removed and replaced without disturbing the rest of the harness, allowing targeted component replacement while leaving the majority of the wire harness in place.
2Ease of repair
If the entire wire harness is removed for component replacement, then the component can be accessed, but other vehicle components must be removed to access the wire harness
Solution Approach 1:
The wire harness is divided into modular sections with disconnectors positioned to create accessible separation points. This segmentation allows technicians to isolate and work on specific harness sections without removing adjacent vehicle components, simplifying the repair procedure.
Solution Approach 2:
The disconnectors are extracted as independent removable components that provide access points within the wire harness. By removing only the disconnector rather than the entire harness or surrounding vehicle components, technicians can access and replace faulty components more directly.
3Ease of repair
If the entire wire harness is replaced for component repair, then the repair can be completed, but the cost increases due to replacing functional components
Solution Approach 1:
The wire harness is segmented into modular sections that can be independently replaced. This allows technicians to replace only the specific segment containing the faulty component rather than the entire harness, preserving functional sections and reducing material waste.
Solution Approach 2:
The faulty section or disconnector is extracted and replaced individually, allowing the majority of the wire harness to be retained and reused. This selective replacement approach minimizes material consumption and reduces repair costs.
Data Source
AI summary
A wire harness for a charging inlet of a vehicle includes first and second high voltage wires having first and second conductors. An inline disconnect electrically connects the first and second conductors and is configured to allow the conductors to be disconnected. The inline disconnect includes a housing having a central cavity, a first chamber at a first end that receives the first high voltage wire, and a second chamber open to the central cavity at a second end that receives the second high voltage wire. First and second disconnect contacts terminated to the conductors are received in the central cavity. A connecting element couples the first and second disconnect contacts and is removable from the disconnect contacts to allow disconnection of the first and second disconnect contacts to electrically separate the first and second high voltage wires.