Modular Wire Harness Segmentation for Automotive Adaptability
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Solution Overview
Problem
The complexity of manufacturing wire harnesses for automobiles with varying specifications leads to redundant circuits and terminal connectors, increasing design and production workload due to the need for multiple part numbers and configurations.
Innovation Solution
A modular wire harness design featuring first and second wiring members with intermediate connectors, allowing for flexible connection configurations and reduction of redundant components by utilizing a common first wiring member with multiple second wiring members tailored to specific specifications, reducing the number of part numbers and simplifying the design process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wire harnesses are manufactured with multiple part numbers to accommodate different automobile specifications, then the adaptability to different specifications is improved, but the device complexity and manufacturing workload increase significantly
Solution Approach 1:
The wire harness is divided into a first wiring member (common to all specifications) and multiple second wiring members (specific to different specifications). This segmentation allows the common infrastructure to be standardized while only varying the specification-specific portions, thereby reducing design complexity while maintaining adaptability.
Solution Approach 2:
The first wiring member is designed as a universal component that can be used across all automobile specifications. By creating a common backbone that serves multiple functions and configurations, the need to redesign entire wire harnesses for different specifications is eliminated, reducing both complexity and workload.
2Adaptability or versatility
If wire harnesses are manufactured with multiple part numbers to accommodate different automobile specifications, then the adaptability to different specifications is improved, but the loss of time and productivity decrease due to increased review workload
Solution Approach 1:
The first wiring member is designed and standardized in advance as a common component. This preliminary action establishes a reusable foundation that eliminates the need for repeated design reviews across different specifications, thereby improving productivity while maintaining adaptability.
3Adaptability or versatility
If the wire harness scale increases to accommodate more circuits and terminals, then the adaptability to modern automobile systems is improved, but the device complexity and difficulty of reviewing design processes increase
Solution Approach 1:
By segmenting the wire harness into scalable first and second wiring members, the system can accommodate increasing numbers of circuits and terminals in a structured manner. The first wiring member provides a stable framework while the second wiring members can be expanded or modified to meet growing system requirements without overwhelming design complexity.
Data Source
AI summary
A wire harness includes: a first wiring member including a plurality of first linear transmission members and at least one first intermediate connector, some of the plurality of first linear transmission members being connected to the first intermediate connector; and a second wiring member including at least one second linear transmission member and a second intermediate connector to which the at least one second linear transmission member is connected. The first intermediate connector and the second intermediate connector are connected to each other, thus at least one part member of plurality of first linear transmission members which are connected to the first intermediate connector are connected to at least one second linear transmission member.