Wire Harness Braided Shield Segmentation for Surge Voltage Control
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Solution Overview
Problem
Existing wire harnesses in vehicles, such as hybrid and electric automobiles, fail to adequately suppress surge voltage due to impedance mismatching between the inverter and motor, leading to excessive noise and radiation issues.
Innovation Solution
A wire harness design featuring three or more electric wires collected in the same direction, surrounded by a braided metallic wire shield that interposes between adjacent wires, forming shield member-shaped correction portions to approach the center axis line and reduce capacitance, thereby effectively shielding noise and surge voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electric wires are closely arranged to reduce space, then compactness is improved, but surge voltage suppression deteriorates
Solution Approach 1:
The wire harness is segmented into multiple regions, each with its own individual braid shielding specific wires. This allows tight packing of wires within each segmented region while maintaining surge voltage suppression through the localized braids, resolving the space versus surge voltage suppression contradiction.
Solution Approach 2:
Different regions of the wire harness have different shielding configurations tailored to local requirements. Individual braids provide localized surge voltage suppression where needed, while allowing compact wire arrangement in other areas, achieving both compactness and surge voltage suppression.
2Ease of manufacture
If a single continuous braid is used to surround all wires, then manufacturing simplicity is improved, but surge voltage suppression deteriorates
Solution Approach 1:
The single continuous braid is divided into multiple individual braids that can be manufactured separately using standard braid manufacturing processes. This segmentation maintains manufacturing simplicity while enabling each braid to independently suppress surge voltage on specific wires, resolving the contradiction between manufacturing ease and surge voltage suppression.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design significantly reduces radiation noise and surge voltage by interposing the braided wire shield between electric wires, maintaining the wire arrangement and ensuring effective noise suppression and long-term surge voltage control.
Implementation Method 1
a shield member which surrounds an outer circumferential side of the electric wire portion in a bundle
Implementation Method 2
which is formed so that the shield member approaches the center axis line side in relation to an outer circumferential tangential line connecting the conductor portions of two electric wires
Data Source
AI summary
A wire harness includes an electric wire portion in which three electric wires are collected in the same direction, a braided wire which surrounds the outer circumferential side of the electric wire portion in a bundle, and an electric wire holding member which maintains the arrangement of the electric wires about a center axis line of the electric wire portion. The electric wire holding member includes a plurality of braided correction portions which protrudes in the direction of the center axis line from an inner circumferential surface of the outer shape holding portion between two adjacent electric wires of the electric wire portion in the circumferential direction about the center axis line, and is formed so that the braided wire approaches the center axis line in relation to outer circumferential tangential lines connecting conductor portions of the two electric wires in a cross-section perpendicular to the center axis line.