Modular Wiring Harness Layout for Scalable Energy Storage
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Solution Overview
Problem
Installing energy storage systems is time-consuming due to the complexity of wiring components together, such as stripping wires and terminating them with connectors.
Innovation Solution
A modular wiring harness system that allows for flexible connection of battery blocks to an inverter, utilizing a trunk harness with spurs and connectors for efficient power, communication, and grounding, enabling scalable energy storage systems with reduced pin count and simplified installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods are used to connect components, then reliable electrical connections are achieved, but installation time increases significantly due to wire stripping and connector termination
Solution Approach 1:
The wiring harness is pre-assembled with all electrical connections, connectors, and routing completed during manufacturing. This preliminary action eliminates the need for on-site wire stripping and connector termination, reducing installation time while maintaining connection reliability through factory-quality assembly.
Solution Approach 2:
The wiring system is divided into modular components: a main trunk harness and separate spur assemblies that can be independently manufactured and then quickly connected. This segmentation allows for pre-assembly of complex wiring sections while enabling simple field installation through modular connection.
2Reliability
If multiple discrete wires are used to connect battery blocks to inverter, then electrical connections are established, but the number of connections and complexity increases
Solution Approach 1:
Multiple individual wire connections are merged into a single integrated wiring harness assembly. The trunk harness consolidates power, communication, and grounding conductors into one organized structure, reducing the number of discrete connections from multiple separate wires to a unified modular assembly.
3Reliability
If traditional wiring harnesses are used, then electrical connections are made, but scalability and adaptability to different system configurations are limited
Solution Approach 1:
The wiring harness incorporates dynamic configurability through selectable spur assemblies that can be added or removed based on system requirements. The modular design allows the same trunk harness to adapt to different numbers of battery blocks and system configurations, providing versatility without compromising connection reliability.
Solution Approach 2:
The trunk harness is designed as a universal platform that can support multiple spur assemblies for different system configurations. The same basic harness structure serves various applications by simply adding or removing spur modules, enabling scalability from small to large energy storage systems.
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 that includes: an inverter-end positive-DC power bus pin, an inverter-end negative DC power bus pin, and an inverter-end neutral power bus pin. It further includes a first spur of the main cable terminating in a first-type battery device connector that includes: a first-type battery module positive-DC power bus pin and a first-type battery device neutral power bus pin. It further includes a second spur of the main cable terminating in a second type battery device connector that includes: a second-type battery module neutral power bus pin and a second-type battery device negative DC power bus pin.