Modular Truck Wiring Harness Eliminates Junction Boxes
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Solution Overview
Problem
The conventional customization process for heavy-duty trucks is labor-intensive, time-consuming, and costly, with issues such as moisture ingress, electrical shorting, and complex wiring diagnostics due to the use of junction boxes, which are not weather-tight and lead to wire corrosion, and the need for extensive soldering and heat shrinking.
Innovation Solution
A wire harness kit with a primary harness and secondary sections that plug into the body builder and upfitter plugs, using braided sleeves and quick connectors to simplify wiring and eliminate the need for junction boxes, soldering, and heat shrinking, allowing for easy installation and future repairs without cutting original wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional customization process with junction box is used, then electrical connections can be made, but installation time is excessive (24-40 hours)
Solution Approach 1:
The wire harness is divided into modular sections with pre-attached connectors for different lighting functions (brake lights, turn signals, parking lights, etc.). Each module can be independently installed and connected to the vehicle's existing harness, eliminating the need for a centralized junction box and extensive wiring work.
Solution Approach 2:
All electrical connections, soldering, and weatherproofing (heat shrinking) are completed during manufacturing of the wire harness modules before delivery to the customer. This preliminary preparation eliminates time-consuming on-site wiring operations and allows for rapid installation by simply plugging connectors into the vehicle's existing harness.
2Reliability
If junction box is used for weather protection, then electrical connections are made, but moisture ingress and wire corrosion occur
Solution Approach 1:
The invention eliminates the junction box entirely and distributes all electrical connections throughout the vehicle by attaching connectors directly to the wire harness modules at their installation locations. This removes the vulnerable centralized enclosure that previously allowed moisture ingress and corrosion.
Solution Approach 2:
Each wire harness module uses flexible weatherproof boots and heat-shrink tubing directly on connectors and wire exposures at the point of connection. This distributed approach to weatherproofing ensures that each connection point is individually protected without requiring a centralized enclosed space, preventing moisture accumulation and corrosion.
3Ease of manufacture
If extensive wiring and soldering is performed, then electrical connections are established, but manufacturing complexity increases
Solution Approach 1:
The wire harness is segmented into functional modules (rear lights, corner posts, dump body lights, etc.), each with pre-attached connectors. This segmentation transforms a complex single-piece wiring task into simpler modular installations that can be independently manufactured, tested, and installed.
Solution Approach 2:
All complex wiring, soldering, and connector attachment operations are performed in advance during manufacturing of the modular wire harness sections. This shifts complexity from the installation phase to the manufacturing phase, where automated processes and quality control can more effectively handle the detailed work, resulting in simpler field installation.
4Reliability
If heat shrinking is used for weatherproofing, then weather resistance is improved, but installation time and cost increase
Solution Approach 1:
All heat shrinking and weatherproofing operations are completed during manufacturing of the wire harness modules before delivery to the customer. This preliminary weatherproofing eliminates the need for time-consuming on-site heat shrinking operations and ensures consistent quality control in a controlled manufacturing environment.
Solution Approach 2:
The invention changes the timing parameter of when weatherproofing is applied - moving it from the installation phase to the manufacturing phase. This parameter change allows weatherproofing to be performed under optimal controlled conditions with proper equipment, reducing both time and cost while improving reliability.
5Ease of repair
If junction box is located underneath frame, then electrical connections are centralized, but accessibility for repairs is difficult
Solution Approach 1:
The invention removes the centralized junction box from underneath the frame and distributes all electrical connections throughout the vehicle by placing connectors at each lighting location. This extraction eliminates the inaccessible enclosed space that previously made diagnosis and repair difficult, allowing technicians to easily access and service each connection point independently.
6Adaptability or versatility
If additional accessories are added after initial customization, then vehicle functionality is enhanced, but connecting more wires to junction box is difficult
Solution Approach 1:
The modular wire harness architecture allows additional accessories to be connected by simply adding new modules with pre-attached connectors to the existing system. Each module operates independently and connects to the vehicle's harness without requiring modifications to existing connections or access to a centralized junction box, maintaining simplicity while enabling expansion.
Data Source
AI summary
A wiring harness system and installation method is provided for customizing a truck chassis to a provide quick and easy addition and repair of electrical features on a completed heavy-duty truck body. The system and method add the existing wires of the chassis, without the need for cutting or disconnecting anything on the chassis. A primary harness connects to the body builder plug and upfitter plug of the chassis and extends along the frame rails to the rear of the truck. One or more extension harnesses can be plugged into the connectors on the primary harness, with various electrical features of the truck body being plugged into the extension harnesses or the primary harness.