Modular Wiring Harness Layout for Faster Battery-Inverter Installation
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Solution Overview
Problem
Installing energy storage systems is challenging due to the time-consuming process of wiring components together, including stripping wires and terminating connectors.
Innovation Solution
A modular wiring harness system that allows for flexible connection of battery blocks to an inverter, using a trunk harness with spurs and connectors that enable daisy-chaining of CAN and ground connections, reducing the number of discrete wires needed and facilitating scalable energy storage systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods are used to connect battery blocks and inverters, then reliable electrical connections are achieved, but the installation process becomes time-consuming and complex
Solution Approach 1:
The wiring system is divided into modular components: a main trunk harness and multiple spur harnesses that can be independently connected to different battery blocks. This segmentation allows installers to connect components in a systematic sequence rather than managing multiple discrete wire connections, significantly reducing installation time while maintaining connection reliability through standardized connector interfaces.
Solution Approach 2:
The wiring harness is pre-assembled with all necessary connections, terminations, and routing configured before installation. The trunk and spur harnesses are pre-configured with appropriate wire gauges, connector types, and length specifications, eliminating the need for on-site wire stripping, bending, and termination work, thus dramatically reducing installation time while ensuring reliable connections.
2Adaptability or versatility
If multiple discrete wires are used to connect battery blocks to the inverter, then flexible routing is achieved, but wire complexity and installation difficulty increase
Solution Approach 1:
Multiple individual wire connections are merged into integrated harness assemblies. The trunk harness combines all main power and communication lines, while spur harnesses bundle connections to each battery block. This merging reduces the number of separate routing decisions and connection points, simplifying the overall wiring complexity while maintaining routing flexibility through the harness's physical configuration.
Solution Approach 2:
The wiring harness acts as an intermediary component between the inverter and battery blocks, consolidating multiple electrical connections into a single manageable unit. The harness with its pre-configured trunk and spurs serves as a mediator that simplifies the interface between components, reducing installation complexity while preserving routing adaptability through modular connector design.
3Adaptability or versatility
If scalable energy storage systems are designed to accommodate varying numbers of battery blocks, then system flexibility is improved, but the wiring configuration becomes more complex
Solution Approach 1:
The wiring system uses segmented spur harnesses that can be selectively connected or disconnected based on the number of battery blocks in the system. Each spur represents an independent connection module that can be added or removed without affecting other connections, enabling scalable configurations from single-block to multi-block systems while maintaining consistent wiring patterns and reducing configuration complexity.
Solution Approach 2:
The trunk harness and spur harnesses are designed as universal components that can serve multiple functions across different system configurations. The same harness design works whether one or many battery blocks are installed, with spurs that can be connected or left unused. This universality allows the system to scale flexibly without requiring different wiring configurations, thereby reducing complexity while improving adaptability.
Data Source
AI summary
A wiring harness for a battery and inverter system includes a main cable. It further includes an inverter connector configured to plug the main cable into an inverter module. It further includes a first spur of the main cable terminating in a first-type battery device connector. It further includes a second spur of the main cable terminating in a second type battery device connector.