Power Distribution Module Wiring Simplification
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Solution Overview
Problem
In mobile equipment, traditional power distribution systems require individual hardwiring of electrical devices, leading to significant effort and downtime when a device malfunctions, as each device must be traced and replaced.
Innovation Solution
A power distribution module with a housing, power input and output ports, a printed circuit board, light emitting diodes, and thermally conductive resin, which provides a central power distribution point, reducing the need for manual wiring and enabling efficient power and signal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual hardwiring is used for each electrical device, then each device can be directly connected to the power source, but the wiring complexity increases and maintenance time increases when a device malfunctions
Solution Approach 1:
The patent consolidates multiple individual hardwired connections into a single power distribution module that interfaces with the vehicle's electrical system through one main connection. The module contains multiple output ports that distribute power to various devices, replacing numerous individual wire runs with a centralized distribution unit.
Solution Approach 2:
The power distribution module serves multiple functions: it acts as a central power distribution point, provides connection interfaces for multiple devices, enables easy device replacement, and incorporates status indication through LEDs. This multi-functional design replaces what would otherwise require separate systems for power distribution, connection management, and status monitoring.
2Ease of operation
If individual hardwiring is used for each electrical device, then direct power connection is achieved, but maintenance effort and downtime increase when a device malfunctions
Solution Approach 1:
The system segments the electrical connection architecture into modular components: the power distribution module, individual device connectors, and output ports. This segmentation allows any single device to be quickly disconnected and replaced by simply unplugging from its output port, without requiring tracing or modification of other wiring connections.
Solution Approach 2:
The wedge-lock mechanism provides automatic locking and sealing when connectors are inserted, and automatic release when the release tab is actuated. This self-service design eliminates the need for tools or complex procedures to connect or disconnect devices, enabling rapid maintenance operations.
3Adaptability or versatility
If multiple connection ports are provided for power distribution, then power can be distributed to multiple devices, but the housing complexity and manufacturing difficulty increase
Solution Approach 1:
Multiple output ports and their associated locking mechanisms, sealing features, and structural elements are integrated into a single housing component. This merging of multiple functions into one molded part simplifies manufacturing compared to assembling multiple separate components, while still providing versatile power distribution capabilities.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support, contains the printed circuit board, houses multiple output ports, incorporates wedge-lock receivers, provides sealing surfaces, and includes mounting features. This multi-functional design reduces the total number of components needed while maintaining adaptability for various power distribution configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The power distribution module simplifies the connection of multiple electrical devices to a vehicle's electrical system, reducing wiring complexity and maintenance time, while withstanding environmental factors like water and vibration.
Implementation Method 1
a light emitting diode connected to the printed circuit board, wherein the light emitting diode is in electrical communication with the input port junction
Implementation Method 2
a thermally conductive resin layer disposed adjacent the printed circuit board and the housing, wherein the thermally conductive resin layer contacts at least a portion of the printed circuit board
Data Source
AI summary
A power distribution module for use on mobile equipment is described in the present disclosure and can include a housing having a power input port and a plurality of output ports integrally formed with the housing and open to an outer surface of the housing. Each of the input port and the output ports are configured to receive and secure a connector that is pushed and locked into place, thereby sealing the connection. The power distribution module can be used to split a single power line into multiple lines connected to electrical devices mounted on a piece of mobile equipment.