Straddle Vehicle Harness Layout Reducing Weight
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Solution Overview
Problem
In motorcycles, the conventional layout of electric components in the electric power supply system results in long harnesses, increasing weight and cost, and making assembly difficult due to the placement of components like the relay box and fuse box under the seat, leading to thick, heavy, and inflexible wiring.
Innovation Solution
Reconfiguring the layout to place the fuel tank and air cleaner rearward, creating a larger electric component mounting space that allows for closer placement of components like the relay box, regulator, and fuse box, reducing harness length and facilitating heat radiation while maintaining sufficient fuel tank volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the relay box and fuse box are placed under the seat in conventional layout, then the components can be accommodated, but the harness becomes long, increasing weight and cost
Solution Approach 1:
The patent relocates the relay box and fuse box from the conventional under-seat position to the front portion of the vehicle body, specifically in the space between the head pipe and the fuel tank/air cleaner assembly. This spatial reconfiguration in a different dimensional arrangement reduces harness length by positioning components closer to each other and to the battery, thereby reducing weight without compromising component accommodation capability
2Ease of manufacture
If the relay box and fuse box are placed under the seat, then the components can be mounted, but the harness becomes thick and difficult to assemble
Solution Approach 1:
By repositioning the relay box and fuse box to the front portion of the vehicle body in a different spatial arrangement, the harness routing becomes more direct and less convoluted. This dimensional reconfiguration allows for easier assembly operations as the thick harness requires fewer bends and navigates a shorter path between components
3Temperature
If the regulator is placed on the air cleaner to block heat, then heat radiation is facilitated, but no extra space remains for other electric components
Solution Approach 1:
The patent segments the vehicle body space into distinct functional zones: the front portion between the head pipe and fuel tank/air cleaner is dedicated to electric components (relay box, fuse box), while the air cleaner area maintains its heat management function. This spatial segmentation allows both heat radiation capability and component accommodation to coexist without interference
Solution Approach 2:
The regulator placement strategy is reconsidered by utilizing the newly created front space for electric components. The air cleaner can maintain its position for heat blocking while the relay box and fuse box are positioned in the front portion, effectively using different spatial dimensions to resolve the space conflict
4Area of stationary object
If the fuel tank is disposed at a rearward position, then electric component mounting space is ensured, but the overall vehicle layout must be reconfigured
Solution Approach 1:
The patent utilizes the space in the front portion of the vehicle body, between the head pipe and the rearward-positioned fuel tank/air cleaner assembly, to accommodate the relay box and fuse box. This three-dimensional spatial optimization creates adequate mounting space for electric components while maintaining a coherent overall vehicle layout that does not require excessive reconfiguration
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
This configuration reduces the weight and cost of harnesses, simplifies assembly, and improves heat management for electric components, while ensuring efficient air intake and protection from rain.
Implementation Method 1
the regulator is placed on an upper surface of an air cleaner in an air-intake system to block heat radiated from the engine placed therebelow, and heat radiation from the regulator is facilitated by air flowing through an interior of the air cleaner
Data Source
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AI summary
In a straddle vehicle such as a motorcycle, a harness in an electric power supply system which is thick, has a great weight, and is not easily mounted can be reduced in length as much as possible so that a weight and cost can be reduced, and an assembling work can be made easier. An air cleaner and a fuel tank are disposed at a relatively rearward position such that the air cleaner and the fuel tank are disposed behind and distant from the head pipe to provide an electric component mounting space between the air cleaner and the fuel tank, and the head pipe, and a regulator, a relay box and a fuse box are disposed in the electric component mounting space. The fuel tank is disposed at a relatively rearward position such that its rear end portion is positioned behind and below a rear end of a main frame.