Vehicle Circuit Body with Segmented Control Boxes
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Solution Overview
Problem
The increasing complexity of vehicle electrical systems leads to a rise in the number of electric wires, size, and weight of circuit bodies, complicating their structure and manufacturing process, resulting in higher costs and longer production times.
Innovation Solution
A circuit body design featuring separate control boxes, trunk line harnesses with separate power and communication lines, and branch line harnesses that differ or are common based on steering wheel position, eliminating the need for junction boxes and simplifying the structure and manufacturing process by using multiplex communication and power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of electrical components and control systems is increased to meet modern vehicle requirements, then the functionality and control capability are improved, but the number of electric wires, circuit body size, and weight increase
Solution Approach 1:
The circuit body is divided into multiple control boxes (power supply control box, signal control box, etc.) that are separately disposed. Each control box independently controls specific functions, allowing modular management of electrical systems. This segmentation reduces the need for extensive wiring between components and enables more efficient power and signal distribution, thereby reducing overall circuit body weight while maintaining enhanced control capability.
Solution Approach 2:
The control boxes are designed to perform multiple functions - power supply control, signal processing, communication management - within single units. This multi-functionality consolidates what would otherwise require separate dedicated circuits and components, reducing the total number of wires and overall circuit body weight while maintaining the required versatility and control capability.
2Adaptability or versatility
If more electrical components and optional configurations are added to accommodate different vehicle types, then the adaptability is improved, but the manufacturing process becomes more complicated and manufacturing cost increases
Solution Approach 1:
The circuit body is segmented into standardized control boxes that can be independently manufactured and then configured for different vehicle types. This modular approach allows base units to be produced using standardized processes, while customization is achieved through selective assembly and configuration rather than custom manufacturing, thereby maintaining ease of manufacture while achieving vehicle type adaptability.
Solution Approach 2:
The control boxes are designed with configurable connections and adaptable interfaces that can be adjusted according to different vehicle specifications. This dynamic configurability allows the same basic control box design to serve multiple vehicle types through software or connection configuration rather than requiring different hardware designs, simplifying the manufacturing process while maintaining adaptability.
3Adaptability or versatility
If the circuit body structure is made more complex to accommodate additional functions and configurations, then the functionality is improved, but the manufacturing time increases
Solution Approach 1:
By segmenting the circuit body into independent control boxes with standardized interfaces, each unit can be manufactured separately using optimized processes. This parallel manufacturing approach reduces overall production time compared to building complex integrated circuits, while the standardized interfaces ensure proper functionality when assembled.
Solution Approach 2:
Control boxes are pre-configured and pre-tested as independent modules before final assembly into the complete circuit body. This preliminary preparation allows manufacturing steps to be performed in advance on standardized components, reducing the time required for final assembly and testing while ensuring proper functionality.
Data Source
AI summary
A circuit body for a vehicle is wired on a vehicle body of the vehicle for performing supply of electric power to an electrical component and communication of various communication signals with the electrical component. The circuit body includes: a plurality of control boxes separately disposed on the circuit body and capable of controlling input and output of at least one of the electric power and the communication signal; a trunk line harness connecting one of the plurality of control boxes and another of the plurality of control boxes; and a branch line harness connecting the control box and the electrical component. The trunk line harness includes a power line for transmitting electric power and a communication line for transmitting communication signals in a separated state. An end portion of the power line and an end portion of the communication line are connected to the control box.