Vehicular Trunk Line Layout for Modular Wire Harness Routing
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Solution Overview
Problem
The complexity of modern vehicle systems, particularly in automatic driving technologies, has led to a complicated structure of wire harnesses, making it difficult to add new electric wires and increasing manufacturing costs due to the need for customized components for various vehicle models and optional accessories.
Innovation Solution
A vehicular circuit body with a simplified trunk line configuration, featuring a power source line and a communication line routed in a vehicle body, and a distribution of control boxes along the trunk line to facilitate power distribution and signal transmission. This configuration allows for easy addition of new electric wires and reduces manufacturing costs by standardizing components across multiple vehicle models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a wire harness with a complex shape is formed by combining trunk line, sub-wire harness, and optional sub-wire harness to connect various electric components, then connection to electric components at various locations can be performed, but the structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The wire harness is divided into a trunk line and multiple sub-wire harnesses that can be independently manufactured and then connected. This segmentation allows each part to be simplified while maintaining overall connectivity to various electric components throughout the vehicle.
Solution Approach 2:
The trunk line is designed as a universal base structure that can accommodate different configurations of sub-wire harnesses for various vehicle models and optional equipment. This multi-functionality allows the same trunk line to serve multiple purposes across different vehicle configurations.
2Power
If the diameter of electric wires and number of electric wires increase due to more electric components, then power and communication requirements are met, but the size and weight of the entire wire harness increase
Solution Approach 1:
By segmenting the wire harness into trunk line and sub-wire harnesses, the electrical load is distributed across multiple smaller bundles rather than one large bundle. This allows for more efficient wire routing and reduced overall material usage.
Solution Approach 2:
The wire harness structure transitions from a single centralized trunk to a distributed multi-dimensional network with the main trunk line and multiple branching sub-harnesses extending in different directions to various electric components.
3Ease of manufacture
If almost all electric wires are collected at a trunk line portion to form the wire harness, then routing is simplified, but the number of bundled electric wires increases and weight increases
Solution Approach 1:
The concentrated trunk line is segmented into a main trunk line and multiple sub-wire harnesses. This reduces the number of wires bundled together at any single location while maintaining routing simplicity through the hierarchical structure.
Solution Approach 2:
Connection boxes serve as intermediary components between the trunk line and sub-wire harnesses, allowing wires to be distributed and organized in intermediate locations rather than all converging at a single trunk line portion.
4Adaptability or versatility
If a new electric component is added to the vehicle, then functionality is enhanced, but a new wire harness with differing type or component number must be designed and manufactured separately
Solution Approach 1:
The trunk line is designed as a universal platform that can accommodate various configurations of sub-wire harnesses and connection boxes. This allows new electric components to be integrated by adding or modifying sub-harnesses rather than redesigning the entire wire harness system.
Solution Approach 2:
The wire harness system is designed to be dynamically configurable, where sub-wire harnesses and connection boxes can be added, removed, or reconfigured based on the specific vehicle model and optional equipment, while the core trunk line remains standardized.
Data Source
AI summary
A vehicular circuit body includes a trunk line that includes a power source line and a communication line, and that is routed in a vehicle body; and a plurality of control boxes that are disposed in a distribution manner along the trunk line. The trunk line includes a first trunk line portion extending in a front-and-rear direction of the vehicle body and a second trunk line portion extending in a leftward-and-rightward direction of the vehicle body. The plurality of control boxes include a branch control box that connects the first trunk line portion and the second trunk line portion, and distributes power from one of the first trunk line portion and the second trunk line portion to the other one.