Vehicle Circuit Trunk Line Reduces Wire Harness Weight
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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 lead to increased manufacturing costs and difficulties in commonizing components, making it challenging to simplify the electric connection structure and reduce size and weight.
Innovation Solution
A circuit design featuring a trunk line with branch lines and subordinate control portions that allow for flexible power distribution and communication, including auxiliary power supplies and changeover circuits to manage power and signal connections efficiently, enabling commonization of components and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of electrical components mounted on the vehicle increases, then the functionality and versatility of the vehicle electrical system is improved, but the wire harness size, weight, and complexity increase
Solution Approach 1:
The patent combines multiple wire harnesses into a single integrated wire harness structure. The trunk line serves as a common power distribution backbone that branches to multiple electrical components, eliminating the need for separate wire harnesses for each component. This merging approach reduces overall wire harness weight while maintaining the ability to serve multiple functions and components.
Solution Approach 2:
The trunk line is designed as a universal power distribution backbone that can serve multiple different electrical components through its branch lines. The same trunk line structure can accommodate various types of electrical components (lights, motors, sensors, etc.) by simply connecting them to different branch points, making the wire harness multi-functional and adaptable to different vehicle configurations.
2Adaptability or versatility
If the number of electrical components mounted on the vehicle increases, then the versatility is improved, but the wire harness complexity and manufacturing cost increase
Solution Approach 1:
The wire harness is segmented into a modular structure consisting of a trunk line and multiple branch lines. Each branch line can be independently connected to different electrical components, allowing the system to be configured for different vehicle types and component arrangements. This segmentation reduces complexity by creating a standardized, repeatable pattern rather than a custom-wired system for each component.
Solution Approach 2:
The standardized trunk line design serves as a universal backbone that can accommodate various electrical components through standardized connection points. This universality allows the same basic wire harness structure to be used across different vehicle models and configurations, reducing manufacturing complexity and enabling commonization of components.
3Power
If the diameter of electric wires increases or the number of electric wires increases, then the power supply capacity is improved, but the wire harness size and weight increase
Solution Approach 1:
Multiple wire functions are merged into a single integrated wire harness structure. The trunk line consolidates the main power distribution path, while branch lines efficiently distribute power to individual components. This merging eliminates redundant wiring and reduces the overall volume required compared to having separate wire harnesses or oversized individual wires.
Solution Approach 2:
The wire harness utilizes three-dimensional routing optimization by arranging wires in multiple spatial dimensions within the vehicle. The trunk line and branch lines are configured to efficiently use available space, routing wires through different layers and pathways to minimize overall volume occupation while maintaining adequate power capacity.
Data Source
AI summary
Power is supplied and a communication path secured by connecting various accessories to branch lines, each of which branches from a main line included in backbone structures. Control of power distribution and the like is implemented by communication between higher-level control units arranged in a smart power supply box, for example, and lower-level control units arranged in area drivers, for example. A switching circuit is arranged at a connection location between the main lines and the branch lines, and is automatically switched such that the terminals to be connected are coordinated. Specifications such as the current of multiple terminals on the power supply side are commonly fixed, and the power to be distributed is controlled by switching the number of terminals to be used. Component standardization and a reduction in part numbers are made easier. The connection position can be freely changed.