Integrated Control Box and Functional Component Module for Vehicle Wire Harness
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Solution Overview
Problem
The increasing complexity of electric components on vehicles leads to a more complex and heavier wire harness structure, with higher manufacturing costs and times, due to the increasing number of electric wires and types of wire harnesses required.
Innovation Solution
A wire harness configuration using trunk and branch harnesses with control boxes that multiplex and demultiplex signals and power, allowing for a single signal and power line, and integrating control boxes with functional components to reduce wire routing and weight, while maintaining functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of electric components on vehicles increases, then the functionality and control capability are improved, but the wire harness structure becomes more complex and heavier
Solution Approach 1:
The patent integrates the control box with functional components (such as switches, sensors, or actuators) into a single unified unit. This merging eliminates the need for separate wiring connections between control boxes and functional components, thereby simplifying the wire harness structure while maintaining the ability to support multiple electric components and functions.
Solution Approach 2:
The control box is designed as a multi-functional unit that can interface with multiple types of functional components through integrated connections. This universal design allows a single control box structure to serve multiple purposes and connect to various electric components, reducing the overall complexity of the wire harness system while accommodating increased functionality.
2Adaptability or versatility
If the number of electric wires and types of wire harnesses increases, then the connectivity to electric components is improved, but the manufacturing cost and manufacturing time increase
Solution Approach 1:
By integrating control boxes with functional components, the patent reduces the total number of separate wiring harnesses required. This consolidation decreases manufacturing complexity, reduces the variety of harness types that must be produced, and lowers both manufacturing costs and production time while maintaining comprehensive connectivity to all electric components.
Solution Approach 2:
The patent segments the wire harness system into modular control box units that are integrated with functional components. This segmentation allows for standardized manufacturing of modular units that can be assembled and connected more efficiently, reducing the overall manufacturing burden compared to producing numerous custom-wired harnesses.
3Productivity
If control boxes are integrated with functional components, then the wire routing steps are reduced and weight is reduced, but the integration complexity increases
Solution Approach 1:
The integration of control boxes with functional components is designed to eliminate multiple assembly steps by pre-establishing electrical connections within the integrated unit. While the internal integration requires careful design, the overall assembly process is simplified because the integrated units can be installed as single modules, reducing the number of routing and connection steps required during vehicle assembly.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A wire harness (1) includes some control boxes (11a-11d) dispersedly arranged on the wire harness; a trunk harness (4a-4h) connecting one of the control boxes to another of the control boxes; and a branch harness (5) connecting the control boxes to the electric components (3a-3i). The control boxes (11a-11d) are configured to be able to multiplex and demultiplex the communication signals. The trunk harness (4a-4h) has a common internal wire structure without relating to the control boxes where the trunk harness is connected. At least one of the control boxes (11a) is integrated with a functional component (12) to be a component module (10). The functional component (12) is configured to be able to input and output information relating to at least one of the electric components.