Vehicle Cable Support Layout for Spacing and Interference Control
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Solution Overview
Problem
Electrified vehicles require effective management of high-voltage electrical cables to prevent interference and maintain versatility, while reducing weight and manufacturing costs.
Innovation Solution
A support system comprising a flange-like structure with adjustable couplers and retaining means that allows for flexible positioning and secure fixation of cables, preventing undesired contact and interference, using a combination of shape-coupled elements and cable ties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable management systems are used in electrified vehicles, then cable support and interference prevention are achieved, but vehicle weight increases and manufacturing costs rise
Solution Approach 1:
The cable support system is divided into multiple individual support elements that can be distributed along the cable path, rather than using a single heavy continuous support structure. Each support element is lightweight but provides localized cable support and spacing functionality.
Solution Approach 2:
The support elements utilize thin-walled cylindrical structures with wall thickness between 0.5-5mm, providing sufficient mechanical support while minimizing material usage and weight. The thin-walled design maintains structural integrity for cable support while reducing overall system mass.
2Reliability
If traditional cable management systems are used, then cable fixation is achieved, but manufacturing costs increase
Solution Approach 1:
The support elements are designed with adjustable parameters including wall thickness (0.5-5mm), length, and positioning that can be optimized based on specific cable requirements and installation locations, allowing cost-effective manufacturing for different applications.
Solution Approach 2:
The support elements serve multiple functions simultaneously: mechanical cable support, electrical insulation, cable spacing maintenance, and interference prevention, eliminating the need for separate components and reducing overall manufacturing cost.
3Adaptability or versatility
If cable support system provides versatility for different cable orientations, then cable management flexibility is improved, but system complexity increases
Solution Approach 1:
The support elements are designed to be positionable at different locations along the cable path and can be oriented to support cables in various directions. This dynamic positioning capability provides versatility for different cable routing requirements without requiring a complex fixed structure.
Solution Approach 2:
The support elements provide three-dimensional cable positioning capability, maintaining spacing in multiple spatial dimensions simultaneously. This allows versatile cable orientation management while keeping each individual support element simple in design.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Support system (1) for supporting at least a wire (W) of a vehicle on a vehicular portion (2) and comprising a support element (5) and a coupler (6), the coupler (6) being configured to be fixedly carried by the vehicular portion (2), the support element (5) comprising a main portion (5') defining a plurality of openings (5"), a first opening (5") being configured to house the coupler (6) and at least a second opening (5") being configured to house a respective wire (W).