Modular Wiring Harness Assembly for Complex Vehicle Circuits
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Solution Overview
Problem
The production and maintenance of complex wiring harnesses in vehicles with numerous electrical circuits are difficult due to their large size, complexity, and the need for specialized equipment and skilled labor, making them costly and inefficient.
Innovation Solution
A modular wiring harness system where each conductor is connected to input and output conductive connectors, allowing modules to be easily combined into a complex circuit, reducing volume and cost, and enabling automated batch production with personalized assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wiring harnesses are produced and assembled separately and then connected, then flexibility in production and assembly is maintained, but connection errors occur and assembly time increases
Solution Approach 1:
The patent combines the wiring harness production and assembly processes into a single integrated operation. The wiring harness is produced and assembled in one continuous process, eliminating the separate connection step that causes errors and delays. This merging of processes maintains production flexibility while ensuring connection accuracy through automated in-line assembly.
Solution Approach 2:
The patent performs preliminary preparation of the wiring harness structure before final assembly. The harness body is pre-formed with connection portions positioned and configured in advance, allowing for accurate and rapid assembly without manual alignment or connection errors during the final assembly stage.
2Productivity
If wiring harnesses are produced and assembled separately and then connected, then production flexibility is maintained, but assembly time increases
Solution Approach 1:
The patent merges wiring harness production and assembly into a single integrated process, eliminating the need for separate connection operations. This reduces assembly time and simplifies the overall assembly process by removing intermediate steps, thereby improving productivity without increasing device complexity.
3Adaptability or versatility
If a large number of wiring harnesses are connected to a control unit, then functionality is improved, but identification of individual harnesses becomes difficult
Solution Approach 1:
The patent applies distinctive local characteristics to each wiring harness connection portion, such as unique positions, shapes, or markings. This allows individual harnesses to be easily identified and distinguished from one another, even when multiple harnesses are connected to the control unit, thereby maintaining harness identification capability while supporting system functionality.
4Volume of moving object
If connection portions are made small to reduce size, then compactness is improved, but positioning accuracy during assembly deteriorates
Solution Approach 1:
The patent incorporates distinctive local features or markings on the connection portions that do not increase their overall size. These local characteristics provide clear positioning references that improve assembly accuracy while maintaining the compact dimensions of the connection portions themselves.
Data Source
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AI summary
A wiring harness module and a combined wiring harness, the wiring harness module including a conductor portion and an insulation portion enclosing the conductor portion. The conductor portion includes at least one conductor, each of which is connected to at least one input conductive connector and at least one output conductive connector. An electrical connection of the conductors of different wiring harness modules is realized by connecting the input conductive connector and the output conductive connector of the different wiring harness modules. The combined wiring harness is formed by splicing a plurality of wiring harness modules in accordance with a preset splicing manner, and the conductors of the plurality of wiring harness modules being electrically connected to each other via the input conductive connector and the output conductive connector. In the present disclosure, each wiring harness module is connected to at least two other wiring harness modules, and each conductor is electrically connected to at least two other conductors, so that a complex conductive circuit is combined.