Multilayer Wiring Panels for Vibration-Resistant Work Vehicle Interconnects
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Solution Overview
Problem
Complex wiring harnesses in work vehicles face issues such as wire abrasion, loosening due to vibrations, and thermal cycling, leading to reliability concerns and increased complexity in manufacturing and maintenance.
Innovation Solution
The implementation of multilayer wiring panels (MWPs) with preplaced wires embedded in a dielectric multilayer panel body, conforming to non-planar mounting surfaces, which reduces the need for extensive wiring harnesses by providing a compact, modular, and reliable electrical interconnection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring harnesses are used to interconnect electronic devices, then electrical connections can be established, but the system becomes complex and prone to wire abrasion, loosening due to vibrations, and thermal cycling issues
Solution Approach 1:
The wiring system is divided into modular multilayer wiring panels that can be independently manufactured, mounted, and replaced. Each panel contains specific wire routes and connections, segmenting the complex wiring harness into manageable units that reduce overall system complexity while maintaining reliable electrical connections.
Solution Approach 2:
Multiple wiring functions are merged into integrated multilayer panels that combine electrical connections, mechanical mounting, and structural support in single components. This consolidation eliminates the need for separate wiring harnesses, mounting brackets, and protective coverings, reducing complexity while improving reliability.
2Stability of the object's composition
If wiring harnesses are secured to engine components using mounting hardware, then the wiring remains fastened during operation, but the manufacturing and installation process becomes more complex
Solution Approach 1:
The mounting function is merged directly into the wiring panel structure itself. The multilayer panels are designed with integrated mounting features that attach directly to engine components, eliminating the need for separate mounting hardware such as clamps, brackets, and fasteners. This integration maintains wiring stability while significantly simplifying manufacturing and installation.
Solution Approach 2:
The wiring panels utilize composite construction combining rigid and flexible materials that provide both structural integrity for mounting and flexibility for wire routing. This composite approach enables direct attachment to engine surfaces without additional mounting hardware while maintaining wiring harness stability under vibration and thermal conditions.
3Adaptability or versatility
If extensive wiring harnesses are used to connect electronic devices, then all necessary electrical connections can be made, but the system becomes harder to maintain and repair
Solution Approach 1:
The wiring system is segmented into modular multilayer panels that can be independently accessed, diagnosed, and replaced. Each panel serves specific electrical interconnection functions, allowing technicians to isolate and repair only the affected panel rather than working with the entire wiring harness. This segmentation maintains full electrical adaptability while dramatically improving ease of repair.
Solution Approach 2:
The modular panel design enables selective replacement of damaged or obsolete wiring panels without replacing the entire wiring system. Individual panels can be discarded when faulty and replaced with updated versions, allowing incremental system upgrades and simplified maintenance while preserving the overall electrical interconnection architecture.
Data Source
AI summary
Work vehicle systems include multilayer wiring panels (MWPs), which provide electrical interconnections to various electronic devices integrated into the work vehicle system. A work vehicle system includes a work vehicle component having a component housing which a first MWP is mounted. The first MWP includes a multilayer panel body having a non-planar cross-sectional shape generally conformal with a topology of a non-planar mounting surface of the component housing, preplaced wires embedded in the multilayer panel body, and panel input/output (I/O) interfaces electrically connected by the preplaced wires. The panel I/O interfaces contain first and second panel I/O interfaces electrically coupled to the controller and to the first integrated electronic device, respectively, such that the controller is placed in signal communication with the first integrated electronic device through the first MWP during operation of the work vehicle system.