Modular Fuel Cell Harness Architecture for Flexible Vehicle Assembly
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Solution Overview
Problem
Existing fuel cell systems face challenges in mass production and customization for various vehicle applications due to complex integration of battery and fuel cell components, requiring a modular architecture that allows for flexible assembly and disassembly without affecting other systems.
Innovation Solution
A modular harness system comprising connectors for battery and fuel cell systems, enabling removable connections between various components such as fuel cell modules, batteries, junction boxes, and hydrogen relay boxes, allowing for easy customization and adaptation to different vehicle configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fuel cell systems use complex integration of battery and fuel cell components, then system functionality is improved, but assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The fuel cell system is divided into modular components including fuel cell modules, battery modules, junction boxes, and hydrogen relay boxes. Each module can be independently assembled and connected through standardized harnesses, reducing overall assembly complexity while maintaining full system functionality.
Solution Approach 2:
The modular harness design serves multiple functions: electrical connection, mechanical support, and alignment guidance. The standardized connector interfaces can accommodate different module configurations, allowing the same harness design to work across various system arrangements and vehicle applications.
2Productivity
If fuel cell systems are designed for mass production, then productivity is improved, but flexibility for customization decreases
Solution Approach 1:
The system uses standardized modular modules that can be pre-assembled and tested independently, then quickly connected using standardized harnesses during final assembly. This enables parallel production workflows and reduces overall build time while maintaining customization capability through different module combinations.
Solution Approach 2:
Modules and harnesses are pre-assembled and pre-tested before final system integration. This preliminary preparation work can be done in parallel during mass production, reducing on-site assembly time and enabling rapid customization of different vehicle configurations from the same production line.
3Ease of operation
If modular connections are used between components, then ease of assembly and disassembly is improved, but connection reliability may worsen
Solution Approach 1:
The modular harness acts as an intermediary component with built-in connectors and routing that mediate between individual modules. The harness includes alignment features, protective routing, and standardized connection interfaces that ensure reliable electrical contact while maintaining ease of assembly through plug-and-play connectivity.
Data Source
AI summary
Systems and methods provide modular harnesses for fuel cell vehicles. An example modular harness may comprise a battery system harness and a fuel cell system harness. The battery system harness may comprise: (a) a battery system harness-to-fuel-cell system harness connector removably connected to a fuel cell system harness-to-battery system harness connector of the fuel cell system harness; and (b) a battery system harness-to-battery connector removably connected to a battery of a vehicle. The fuel cell system harness may comprise: (a) the fuel cell system harness-to-battery system harness connector; and (b) a fuel cell system harness-to-fuel cell module harness connector removably connected to a fuel cell module harness-to-fuel cell system harness connector of a fuel cell module harness.