Inline Power Connector for EV Cable Harness Weight Reduction
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Solution Overview
Problem
Power connector systems in electric vehicles face challenges in routing numerous cable harnesses, which add weight and cost, and require a reduced part count for reliable operation.
Innovation Solution
The implementation of an inline power connector system with a daisy chain architecture that uses a single power cable harness to connect multiple vehicle subsystems, reducing the number of connectors and cable size, and incorporating a socket assembly with a busbar and socket terminal, along with an inline shield and outer housing for efficient power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple cable harnesses are used to connect battery to each device and subsystem, then power transmission reliability is improved, but system weight and cost increase
Solution Approach 1:
The patent combines multiple cable harnesses into a single integrated power cable that distributes power to multiple devices and subsystems. This single cable contains multiple conductors that replace the need for separate cable harnesses, thereby reducing overall weight while maintaining reliable power transmission to all connected components.
Solution Approach 2:
The power cable is designed with multi-functional capability to serve multiple devices and subsystems simultaneously. A single cable harness performs the function of multiple separate cables by incorporating multiple conductors and connection points, enabling one cable to power various components including motors, sensors, and control units.
2Adaptability or versatility
If multiple cable harnesses are used to connect battery to each device and subsystem, then power distribution capability is improved, but system cost increases
Solution Approach 1:
The invention merges multiple cable harnesses into a single integrated power cable assembly, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation lowers manufacturing costs while maintaining the ability to distribute power to multiple devices through the multi-conductor design.
Solution Approach 2:
The universal power cable design provides adaptability to connect to various devices and subsystems through its multiple conductors and configurable connection points. This multi-functional approach eliminates the need for device-specific cable harnesses, reducing overall system cost while maintaining versatile power distribution capability.
3Adaptability or versatility
If numerous cable harnesses are routed between battery and devices, then power transmission flexibility is improved, but routing complexity increases
Solution Approach 1:
By combining multiple cable harnesses into a single integrated power cable, the invention significantly reduces routing complexity. Instead of managing multiple separate cables that need to be routed individually through the vehicle, the single consolidated cable simplifies the routing path and reduces installation complexity while maintaining flexible power distribution to multiple devices.
4Device complexity
If a single power cable is used to connect multiple subsystems, then part count is reduced, but connector reliability requirements increase
Solution Approach 1:
The patent reduces part count by consolidating multiple cable harnesses and connectors into a single integrated power cable assembly. This reduction in the number of connection points and components simplifies the system while the robust design of the integrated connector ensures maintained reliability through careful engineering of the connection interfaces.
Data Source
AI summary
An inline power connector for a power cable harness includes a socket assembly having a busbar, a socket terminal, and first and second cable terminators at opposite ends terminated to corresponding first and second cables of the power cable harness. The inline power connector includes an inner housing holding the socket assembly and an inline shield surrounding the inner housing and coupled to cable shields of the cables. The inline power connector includes an outer housing having a cavity receiving the inline shield, the inner housing, and the socket assembly. The cables extend into opposite ends of the outer housing. The outer housing includes a hub inline between the first end and the second end configured to receive a pin terminal that is configured to be coupled to the socket terminal of the socket assembly.