Flat Seat Wire Harness Layout for Optional Device Routing
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Solution Overview
Problem
The complexity of manufacturing and routing wire harnesses increases with the number of optional devices in vehicle seats due to the need for intricate connections and space management.
Innovation Solution
A wire harness design with a base harness that includes a protective member keeping electric wires flat, branching into three lines with dedicated connectors for common and optional devices, allowing flexible power supply and efficient routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of optional devices in the seat is increased, then the versatility and functionality of the seat is improved, but the complexity of manufacturing and routing the wire harness increases
Solution Approach 1:
The wire harness is segmented into a base harness and multiple optional harnesses. The base harness contains common components for all seats, while optional harnesses are added only when needed. This segmentation allows the base harness to remain simple and easy to manufacture, while still supporting multiple optional devices through modular additions.
Solution Approach 2:
The base harness is designed with universal connectors and routing paths that can accommodate multiple different optional devices. The third connector and its associated third branch line can connect to various optional devices (heating, cooling, massage functions), allowing the same base harness structure to serve multiple functions without increasing its own complexity.
2Adaptability or versatility
If more connectors and branch lines are added to support optional devices, then the adaptability to different device configurations is improved, but the device complexity and space requirements increase
Solution Approach 1:
The optional harnesses are designed to be nested or integrated with the base harness structure. The optional harnesses connect to the base harness at specific points (through the third connector) and follow routing paths that are already established in the base harness, allowing them to be nested within the existing structural framework rather than requiring completely separate routing paths.
Solution Approach 2:
The wire harness routing utilizes the third dimension (vertical space) by routing harnesses above and below the seat cushion. This allows multiple connectors and branch lines to be accommodated without increasing horizontal complexity, as components are arranged in different vertical layers rather than competing for the same planar space.
3Adaptability or versatility
If the wire harness is designed to accommodate multiple optional devices, then the future expandability is improved, but the initial manufacturing complexity and cost increases
Solution Approach 1:
The base harness is manufactured in advance with pre-positioned connectors (including the third connector) and pre-routed branch lines, even though the optional devices may not be selected until later. This preliminary preparation of the base harness structure allows for easy addition of optional harnesses later without requiring complex modifications to the base harness itself.
Solution Approach 2:
The wire harness system is designed to be dynamic rather than static. The base harness remains constant and simple to manufacture, while the optional harnesses can be added or removed based on customer selection. This dynamic configuration allows the system to adapt to different device requirements without requiring a completely different base harness design for each configuration.
Data Source
AI summary
The wire harness includes a base harness having a plurality of electric wires and a protective member. The plurality of electric wires branch into three or more branch lines inside the protective member, and are kept flat by the protective member. The three or more branch lines include a first branch line provided with a first connector for receiving power supply from an upstream side, a second branch line provided with a second connector for supplying power received by the first connector to a device provided in the seat, and a third branch line provided with a third connector for supplying the power received by the first connector to an optional device provided in the seat.