Retrofit Wire Harness Branch Connection Mechanism
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Solution Overview
Problem
Existing wire harness structures face inefficiencies and increased costs due to the need for multiple item numbers and waste generation when adding additional electrical devices, as they require full-length harnesses and complex assembly, leading to complicated assembly processes and difficulty in replacing or repairing devices.
Innovation Solution
A wire harness structure with a main harness and branch connection mechanism that allows for retrofitting of additional electrical devices using a branch connection member with pressure contact connections, enabling easy addition, replacement, and control of devices without generating waste, by using a single item number for all configurations and minimizing the length of the trunk harness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple wire harness item numbers are prepared for different additional electrical device configurations, then adaptability to various device additions is improved, but device complexity and assembling work complexity increase
Solution Approach 1:
The wire harness is divided into a main harness and separate branch connection mechanisms. The main harness contains only the trunk harness routed on the vehicle, while branch connection mechanisms are added separately for each additional electrical device. This segmentation allows the base harness to remain simple while enabling flexible addition of devices without increasing overall system complexity.
Solution Approach 2:
A single main harness design serves as the universal base for all vehicle configurations, regardless of which additional electrical devices are installed. The branch connection mechanisms are added on top of this universal base, allowing one main harness item number to accommodate multiple device configurations without requiring separate harness designs.
2Adaptability or versatility
If full-length wire harnesses are used to accommodate additional electrical devices, then adaptability is improved, but loss of substance increases due to waste portions
Solution Approach 1:
The wire harness is segmented into a compact main harness and separate branch connection mechanisms. The main harness contains only the essential trunk harness routed on the vehicle, minimizing its length. Additional electrical devices are connected through separate branch connection mechanisms that are added only when needed, eliminating the need for full-length harnesses and reducing material waste.
Solution Approach 2:
The main harness is designed and manufactured with the minimum necessary length for the trunk harness routed on the vehicle, without pre-including unnecessary branches for potential additional devices. The branch connection mechanisms are prepared separately and added only when specific additional electrical devices are installed, preventing waste of unused wire portions.
3Ease of operation
If additional electrical devices are connected by pressure contact to full-length wire harnesses, then ease of operation is improved, but reliability deteriorates due to damaged insulating coating or conductor
Solution Approach 1:
The connection function is segmented from the main harness into separate branch connection mechanisms. These mechanisms are designed with dedicated connection structures that properly protect the insulating coating and conductor during connection operations, preventing the damage that would occur with direct pressure contact to the main harness.
Solution Approach 2:
Branch connection mechanisms serve as intermediary components between the main harness and additional electrical devices. These intermediaries provide proper connection interfaces that protect the insulating coating and conductor of the main harness from damage during connection operations, while still enabling easy connection of additional devices.
4Device complexity
If branch wire harnesses are discarded when not needed, then device complexity is reduced, but loss of substance increases due to discarded harnesses
Solution Approach 1:
The wire harness system is segmented into a permanent main harness and optional branch connection mechanisms. The main harness is retained in all configurations as it contains the essential trunk harness. Branch connection mechanisms are added or removed based on specific device requirements, but the main harness is never discarded, eliminating waste while maintaining simplicity.
Solution Approach 2:
A single universal main harness design serves all vehicle configurations. Instead of discarding branch harnesses for different item numbers, the same main harness serves as the base for all configurations, with branch connection mechanisms added only when needed. This eliminates the waste of discarded harnesses while maintaining low complexity.
Data Source
AI summary
A wire harness structure includes a main harness that has a trunk harness routed on a vehicle, and has at least one branch harness having one end connected to the trunk harness as a branch and the other end electrically connected to an electrical device mounted on the vehicle; and a branch connection mechanism to which at least one additional electrical device mounted on the vehicle is electrically connected, and which is connected to the main harness in a retrofitting manner as a branch.