Vehicular Circuit Body Modular Trunk Line

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Solution Overview

Problem

The increasing complexity and weight of vehicle wire harnesses due to the growing number of electric components make it difficult to manufacture and modify the wiring structure, especially when adding new electric wires, leading to increased costs and manufacturing time.

Innovation Solution

A vehicular circuit body with a simplified trunk line configuration using strip metal power source lines and communication lines stacked with insulators, allowing easy addition of new wires and flexible routing, and including backup power sources and branch lines for efficient power distribution and communication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the number of electric components mounted on a vehicle increases, then the functionality and power supply coverage are improved, but the wire harness size and weight increase

Engineering Contradiction:

Improvepower supply coverageVSAvoidwire harness weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The invention divides the wire harness into modular units: a trunk line serving as the main power distribution backbone, and multiple detachable branch lines that can be independently connected to control units. This segmentation allows the system to scale functionality by adding or removing branch lines without increasing the weight of the core trunk line structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The trunk line is designed as a universal power distribution backbone that can serve multiple different control units and branch lines. The standardized connection interfaces enable the same trunk line to support various configurations of electric components, achieving multi-functionality without requiring separate wire harnesses for each configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Quantity of substance

If the number of electric wires increases to support more electric components, then the power supply capability is improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvenumber of electric wiresVSAvoidwire harness structure

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The wire harness is segmented into a fixed trunk line and detachable branch lines. The trunk line contains the common power supply wires that remain constant regardless of the number of electric components. Branch lines are added or removed based on specific vehicle configurations, allowing the total wire quantity to scale without increasing the complexity of the core trunk line structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The trunk line is pre-manufactured with standardized connection points and routing before vehicle assembly. This preliminary preparation allows branch lines to be simply connected to predetermined locations on the trunk line, significantly reducing manufacturing complexity compared to creating custom wire harnesses for each vehicle configuration.

Inventive Principle:

Principle #10Preliminary action

3Shape

If a bundle of electric wires is pulled around over a long distance to achieve predetermined routing shape, then the routing flexibility is improved, but the work time and manufacturing complexity increase

Engineering Contradiction:

Improverouting shapeVSAvoidmanufacturing work time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The routing is segmented into the trunk line's fixed path and branch lines that connect at standardized points. The trunk line is manufactured once with its predetermined routing shape, and branch lines are simply attached at connection points rather than requiring re-routing of the entire wire harness, significantly reducing manufacturing work time.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The trunk line's routing shape is predetermined and pre-formed during manufacturing, with connection points prepared in advance. This preliminary action eliminates the need for time-consuming field adjustments and allows branch lines to be quickly connected to the pre-routed trunk line structure.

Inventive Principle:

Principle #10Preliminary action

4Stability of the object's composition

If almost all electric wires are collected at a trunk line portion, then the wire harness organization is improved, but the weight and complexity increase

Engineering Contradiction:

Improvewire harness organizationVSAvoidtrunk line weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The trunk line serves as a universal backbone that organizes all power distribution functions in a single standardized structure. By concentrating organization functions in the trunk line while keeping branch lines detachable and minimal, the system achieves high organization without the weight penalty of a fully integrated wire harness containing all wires.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10882476B2Vehicular circuit body

Publication Date: 2021.01.05 YAZAKI CORP

AI summary

A vehicular circuit body includes a plurality of backbone control boxes, a backbone trunk line portion connecting the backbone trunk line portions to each other, and a branch line sub-harness. A trunk includes has a power source line and a communication line, and a control includes a trunk line connection portion and a branch line connection portion.