Modular Vehicle Heater Control Device with Receptacle Tunnel
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Solution Overview
Problem
Existing vehicle heater control devices have high manufacturing costs due to rigidly integrated cable harnesses, limiting design variability and requiring costly, vehicle-specific solutions.
Innovation Solution
A control device with a circuit assembly unit and external receptacle tunnel that allows for a cost-effective, modular cable harness connection to the vehicle wiring system, featuring a holding meshing formation for stable integration with the heater housing and integral design for reduced components and enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable harness is rigidly integrated with the control device, then the connection is stable, but the manufacturing cost increases and design variability decreases
Solution Approach 1:
The cable harness is separated from the control device into independent components. The control device has a standardized receptacle, while the cable harness has a corresponding plug, allowing them to be connected without rigid integration. This segmentation enables different cable harness configurations for different vehicles while maintaining connection stability through the plug-receptacle interface.
Solution Approach 2:
The control device is designed with a universal receptacle that can accommodate different cable harness configurations. The standardized interface allows the same control device to be used across multiple vehicle models with different wiring requirements, increasing design variability while maintaining reliable electrical connections.
2Reliability
If the cable harness is rigidly integrated with the control device, then the connection is stable, but the manufacturing cost increases
Solution Approach 1:
By separating the cable harness from the control device, each component can be manufactured independently using standardized processes. The control device is produced with a universal receptacle, and cable harnesses are manufactured separately and connected via plugs, reducing tooling costs and enabling economies of scale.
Solution Approach 2:
The modular design allows the control device to be reused across different vehicle applications with different cable harnesses. Instead of manufacturing dedicated integrated assemblies for each vehicle model, the universal control device can be recovered and reused, significantly reducing manufacturing costs.
3Device complexity
If the external receptacle tunnel is integrated with the housing, then the number of components is reduced, but the sealing requirement increases
Solution Approach 1:
The external receptacle tunnel is integrated directly into the control device housing as a single molded piece. This merging of components eliminates separate tunnel structures and reduces the total number of parts, while the integral design allows for continuous sealing surfaces that maintain protection against contaminants and moisture.
Data Source
AI summary
A control device for a vehicle heater includes a circuit assembly unit (12) with a plurality of external contacts (24), an external receptacle (30) for receiving an external plug (42) for establishing an electrical contact with the external contacts (24) for connecting the control device (10) to a vehicle wiring system, as well as a circuit assembly unit housing (18) surrounding the circuit assembly unit (12) with an external receptacle tunnel (52) surrounding at least partially the external receptacle (30).