Vehicle Network Wiring Harness Layout Using Matrix Couplers
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Solution Overview
Problem
The complexity of vehicle network systems, particularly in wiring harness production, leads to quality and safety issues due to deep interdependence of connections, making manual production time-consuming and error-prone, and challenging to meet the demands of functional safety requirements.
Innovation Solution
Applying graph theory to divide the vehicle network into topology levels, using a matrix coupler to simplify connections into a bipartite graph structure, which reduces complexity and enables automated production by representing connections as point-to-point links, eliminating the need for manual re-plugging and complex assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual production of wiring harnesses is used, then flexibility in handling complex connection configurations is maintained, but production time increases and error rates rise
Solution Approach 1:
The wiring harness production is divided into modular segments corresponding to different topology levels. Each module can be independently produced and tested, then automatically assembled with other modules through standardized interfaces, enabling both handling of complex configurations and improved productivity through parallel production.
Solution Approach 2:
The patent transforms the complex multi-to-many connection relationships into a standardized topology-level parameter system where connections are defined by hierarchical levels rather than individual wire mappings. This parameter transformation enables automated production systems to handle complexity through systematic rules rather than manual configuration.
2Ease of operation
If manual production of wiring harnesses is used, then complex connection configurations can be handled, but quality and robustness control becomes difficult
Solution Approach 1:
By segmenting the wiring harness into topology-level modules, each module can be independently quality-checked and tested before final assembly. This modular approach enables systematic quality control at multiple stages rather than relying solely on final inspection of the complete complex harness.
Solution Approach 2:
The patent implements automated testing and validation systems that provide feedback during the production process. Each topology-level module undergoes automated continuity testing and connection validation, with results fed back to control the assembly process, ensuring quality control without manual intervention.
3Adaptability or versatility
If the wiring harness structure with deep linkage of connections is maintained, then functional requirements are met, but complexity increases making production error-prone
Solution Approach 1:
The deep linkage connection structure is segmented into hierarchical topology levels. Each level represents a specific functional grouping of connections, reducing the apparent complexity while maintaining the underlying deep interconnections needed for functional requirements. The segmentation makes the complex structure manageable through systematic organization.
Solution Approach 2:
Topology-level modules act as intermediaries between the power source/control units and the final loads. These intermediary modules simplify the connection interface while maintaining the complex functional linkages behind them, allowing automated production systems to work with simplified interfaces rather than complex point-to-point connections.
4Productivity
If automated production is implemented, then productivity increases and errors are reduced, but the system requires simplified connection structures
Solution Approach 1:
The patent transforms complex multi-to-many connection relationships into a standardized topology-level parameter system. This parameter transformation enables automated production systems to handle what appears as simplified hierarchical connections while actually representing the full complexity of the original wiring harness through systematic parameter mapping.
Data Source
AI summary
A network for a vehicle and a method of making the network is described. The network is suitable for a number of vehicle network subscribers in at least two topology levels which can be distinguished spatially or functionally. An energy supply device, at least one control unit, at least one interface module, a communication interface; a number of load interfaces, at least one load interface, at least one matrix coupler are provided. The matrix coupler is set up to represent an unbundling task for linking the vehicle network subscribers, where nodes of a line-connector relationship of the graph representing the matrix-coupler in each case denotes a load interface of the number of load interfaces at the end of a line. Here, an edge of the graph denotes a connection relationship of at least one line between a first load interface and a second load interface.