Vehicle Circuit Routing System Backbone Trunk Line
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Solution Overview
Problem
The increasing complexity and weight of wire harnesses in vehicles due to the growing number of electrical components make it difficult to manufacture and maintain, especially when adding new components or wires, leading to increased costs and complexity in routing and connecting electrical components.
Innovation Solution
A circuit routing system featuring a backbone trunk line with a belt-like configuration, including a power supply busbar, ground busbar, and communication cable, with branch lines and connection points that allow for easy connection and reconfiguration of electrical components, and the use of fuses for overcurrent protection, simplifying the structure and enabling easy addition of new wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of electrical components is increased to meet growing vehicle functionality requirements, then the vehicle's electrical system capabilities are improved, but the wire harness complexity and weight increase
Solution Approach 1:
The wire harness is divided into multiple sub-harnesses (first sub-harness, second sub-harness, etc.) that can be independently routed and connected. Each sub-harness serves specific electrical components in different vehicle regions, reducing the complexity of managing a single large harness while supporting increased component density
Solution Approach 2:
The trunk line is designed as a universal backbone structure that can accommodate multiple types of connections (power supply, ground, signals) and support various sub-harness configurations. This universal trunk line design allows the same basic structure to serve different vehicle models and component arrangements without requiring complete harness redesign
2Adaptability or versatility
If the number of electrical components is increased, then vehicle functionality is improved, but the wire harness weight increases
Solution Approach 1:
By segmenting the wire harness into multiple lighter sub-harnesses connected to a common trunk line, the overall weight distribution is optimized. Each sub-harness can be minimized in size and weight by including only the necessary wires for its specific components, rather than running all wires throughout the entire vehicle
Solution Approach 2:
Multiple sub-harnesses share a common trunk line structure, eliminating redundant wiring. The trunk line serves as a shared backbone that multiple sub-harnesses can connect to at different points, reducing the total wire length and weight compared to having separate harnesses for each component group
3Shape
If electric wires are routed for long distances to finish the wire harness with predetermined routing shape, then the routing shape is achieved, but the work time increases
Solution Approach 1:
By dividing the wire harness into sub-harnesses, each with shorter routing distances to their respective components, the overall work time is reduced. Each sub-harness can be routed and installed independently over shorter distances, then quickly connected to the trunk line, rather than routing one long continuous harness throughout the vehicle
Solution Approach 2:
The trunk line serves as a centralized backbone structure that changes the routing dimension from multiple long individual paths to a centralized hub-and-spoke model. Sub-harnesses connect to the trunk line at optimal points, reducing the total routing distance and simplifying the shaping process compared to traditional distributed routing
Data Source
AI summary
This vehicle circuit routing system as a whole has a backbone-like routing structure, said system being provided with a plurality of backbone JB structures, wherein the vehicle circuit bodies of the backbone JB structures are connected to each other by means of a backbone main line. Each vehicle circuit body is provided with a power supply circuit that is connected to a main power supply on the vehicle, a plurality of connection parts to which a plurality of branch lines having a power supply line are connected, and a control unit that controls the distribution of power from the power supply circuit to the branch lines.