Vehicle Lighting Control Unit Wire Reduction via Integrated Connector
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Solution Overview
Problem
Conventional load control systems require multiple wires connecting loads directly to a connector with a built-in control unit, leading to increased size and complexity, as well as unnecessary wire routing, which hinders weight savings and space utilization.
Innovation Solution
A load control unit where the connector with a built-in controller is mounted on a single substrate, allowing the circuit pattern to replace redundant wires, thereby reducing the number of wires needed and optimizing space usage by using multiplex communication lines for control signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wires connect loads directly to a connector with a built-in control unit, then control reliability is improved, but device complexity and wire quantity increase
Solution Approach 1:
The patent combines the control unit with the connector into a single integrated component. The control unit is mounted on the connector's housing or base, allowing the connector to serve dual functions: electrical connection and control signal processing. This integration eliminates the need for separate wire routing between independent control units and connectors, reducing wire quantity and routing complexity while maintaining control reliability.
Solution Approach 2:
The connector is designed to perform multiple functions: it provides electrical connection for power and signal transmission, and simultaneously houses the control unit that processes control signals. This multi-functional design reduces the overall number of components and wires needed in the system, as the connector becomes a universal element combining connection and control capabilities.
2Reliability
If multiple wires are routed in parallel to connect loads to the control unit, then control signals are transmitted reliably, but weight and space consumption increase
Solution Approach 1:
By integrating the control unit with the connector, the patent reduces the length and quantity of wires needed. The control unit is positioned at the connector location, eliminating the need for long parallel wire runs from distant control units to multiple loads. This integration significantly reduces wire harness weight while maintaining signal transmission reliability through direct electrical connections at the connector.
3Manufacturing precision
If wires are routed individually from each load to the main control unit, then control precision is improved, but the number of wires and routing complexity increase
Solution Approach 1:
The patent merges the control unit with the connector, allowing individual load control signals to be processed at the connector location rather than requiring separate wire routing to a distant main control unit. This integration maintains control precision by providing dedicated control pathways for each load while eliminating the need for complex long-distance wire routing, as the control unit is co-located with the connector.
Data Source
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AI summary
In a load control unit, three R, G, and B LED chips that constitute each light source (33a-33d) of reading lamps (25-31) and a connector (35) with a built-in controller are mounted on a circuit board (37) to thereby eliminate the connection of a controller (35b) built into the connector (35) with the built-in controller and the respective light sources (33a-33d) by signal lines. In addition, the controller (35b) and a lighting ECU (43) are connected by a multiplex communication line (39), and the multiplex communication line (39) is routed in pillars (15, 17) of a vehicle (1). Consequently, the number of wires can be reduced compared with when individual wires connected to the respective light sources (33a-33d) are passed through the pillars (15, 17), and thereby making it possible to effectively use limited spaces within the pillars (15, 17) through which many other wires are passed.