Wire Harness Aluminum Copper Weight Diameter
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Solution Overview
Problem
Existing wire harnesses face challenges in reducing both weight and diameter simultaneously due to the lower conductivity of aluminum electric wires compared to copper, leading to increased size requirements and space constraints in vehicle mounting.
Innovation Solution
A wire harness design that combines aluminum and copper electric wires of varying diameters, including large, small, and extra fine wires, where aluminum wires are used for high current circuits and copper wires are used for signal circuits, with cross-sectional areas optimized to reduce the overall diameter and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum electric wires are used to replace copper electric wires, then weight is reduced, but diameter increases due to lower conductivity requiring larger wire size
Solution Approach 1:
The patent applies local quality by differentiating wire material selection based on specific circuit requirements. High-current circuits use aluminum wires optimized for current carrying capacity, while low-current signal circuits use copper wires or thinner aluminum wires. This localized material optimization allows the wire harness to achieve weight reduction without uniformly increasing diameter across all circuits.
Solution Approach 2:
The patent changes the parameter of wire cross-sectional area based on conductivity requirements. By carefully selecting appropriate wire gauges for aluminum wires in different circuit contexts, the design maintains electrical performance while minimizing diameter increase. The parameter optimization ensures that aluminum wires are used at sizes that balance weight reduction benefits against diameter constraints.
2Reliability
If wire size is increased to compensate for lower aluminum conductivity, then electrical performance is maintained, but space for mounting increases
Solution Approach 1:
The patent applies local quality by matching wire material and size to specific electrical performance requirements of different circuits. High-current circuits receive appropriately sized aluminum wires to maintain current carrying capacity, while low-current circuits use smaller wires or copper alternatives. This localized optimization maintains overall electrical performance while minimizing total mounting space.
Solution Approach 2:
The patent uses composite materials by combining aluminum and copper wires within the same wire harness system. This composite approach allows optimization of each material's properties for its intended application - aluminum for weight-sensitive high-current circuits and copper for performance-critical low-current circuits - thereby maintaining electrical performance without requiring uniform size increases across all wires.
Data Source
AI summary
A wire harness includes a group of first electric wires connected to a first circuit and a group of second electric wires connected to a second circuit whose consumption current is smaller than that of the first circuit. The group of first electric wires include aluminum electric wires. The group of second electric wires include a large diameter electric wire having a conductor formed of aluminum or aluminum alloy, a small diameter electric wire having a conductor formed of copper or copper alloy and a cross-sectional area of the conductor thereof smaller than that of the large diameter electric wire, and an extra fine electric wire having a conductor formed of the copper or copper alloy and a cross-sectional area of the conductor thereof smaller than that of the small diameter electric wire.