Vehicle Floor Current Rails for Wiring Harness Simplification
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Solution Overview
Problem
Conventional wiring harnesses in motor vehicles are complex to manufacture and install due to varying conductor lengths and cross-sections, making it difficult to connect electrical users, especially those located far from the battery, which is often mounted in the engine compartment.
Innovation Solution
The use of double-function support elements that act as both mechanically stable structural components and electrical 'current rails' with contact points along their entire length, allowing for direct and efficient connection of electrical users to the battery, regardless of its position, using materials like aluminum or copper alloys and insulation for conductivity and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wiring harnesses are used to connect electrical users to the battery, then electrical connections can be established, but the manufacture and installation become complicated due to varying conductor lengths and cross-sections
Solution Approach 1:
The support elements serve dual functions: they provide mechanical support for the vehicle superstructure and simultaneously function as electrical conductors (current rails). This eliminates the need for separate wiring harnesses, significantly simplifying both manufacture and installation while reducing device complexity.
Solution Approach 2:
The patent combines the structural support function and electrical conduction function into a single integrated component (the support elements). By merging these two previously separate functions, the wiring harness complexity is eliminated and the overall system becomes simpler to manufacture and install.
2Volume of moving object
If the battery is mounted in the engine compartment, then space is optimized, but the connection to electrical users in the rear portion becomes complicated due to long conductor lengths
Solution Approach 1:
The support elements are divided into multiple segments with contact points distributed along their entire length. This segmentation allows electrical users at different positions (front, middle, rear) to connect at nearby contact points rather than requiring long continuous conductors from the battery, reducing overall conductor length while maintaining space optimization.
Solution Approach 2:
The support elements act as intermediary current rails between the battery and electrical users. Instead of running long conductors directly from the battery to rear users, the support elements provide intermediate connection points along the vehicle length, reducing the required conductor length while maintaining the battery's optimal engine compartment position.
3Reliability
If individual conductors are used to connect each electrical user to the battery, then electrical connections are established, but the installation becomes complicated especially for rear portion users
Solution Approach 1:
The support elements serve as both structural supports and electrical conductors with multiple contact points. This allows any electrical user at any position along the vehicle to connect to the nearest contact point, simplifying installation while maintaining reliable electrical connections without requiring complex individual conductor routing from the battery.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the connection of electrical users throughout the vehicle, reducing complexity and length of electrical lines, particularly benefiting rear and engine compartment installations by providing a stable and conductive pathway for current transmission.
Implementation Method 1
electrically conductive guide members are arranged in the bottom part of the motor vehicle, which at one of their ends are each electrically conductively connected to one of the poles of the voltage source
Data Source
AI summary
An arrangement is provided for the current supply of electrical users arranged in a motor vehicle. At least two mechanically stable and electrically conductive support elements (4, 5) are arranged in the bottom portion of the motor vehicle (1), where the support elements (4, 5) extend essentially over the entire length of the motor vehicle (1). The two support elements (4, 5) are at one end thereof, each electrically conductively connected to one of the poles of the voltage source (2) and have over their entire length contact points (6, 7) which are separate from each other for connection of the users.