Wire Harness Vertical Conductor Positioning for Road Impact Protection
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Solution Overview
Problem
High-voltage wire harnesses in hybrid electric and electric vehicles are prone to damage from road hazards, leading to potential high-voltage electric current leaks, posing safety risks and reliability concerns.
Innovation Solution
A wire harness design with a high-priority high-voltage conductor path and a low-priority low-voltage conductor path, where the high-voltage path is positioned farther away from the road surface within a predetermined range, utilizing a tubular external member to protect both paths, allowing the low-voltage path to absorb impact and prevent high-voltage path damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the high-voltage conductor path is positioned closer to the road surface to simplify routing, then the routing length is reduced, but the safety and reliability deteriorate due to increased risk of damage from road hazards
Solution Approach 1:
The patent applies dimensional arrangement by positioning the high-voltage conductor path in the vertical dimension (higher from road surface) while the low-voltage conductor path is positioned lower. This spatial separation in the vertical dimension protects high-voltage conductors from road hazards while maintaining routing efficiency, resolving the contradiction between routing length and safety.
2Reliability
If additional protective members are added to protect the high-voltage conductor path, then the safety and reliability improve, but the weight, cost, and manufacturing complexity increase
Solution Approach 1:
The patent merges the protective function into the existing external member structure by strategically positioning the high-voltage conductor path higher within the same external member that already protects the low-voltage conductor path. This combines protection functions without adding separate protective components, reducing complexity while maintaining safety.
Solution Approach 2:
By using vertical positioning within the external member rather than adding external protective structures, the patent achieves protection through spatial arrangement in the vertical dimension, avoiding additional components and their associated complexity.
3Reliability
If the high-voltage conductor path is positioned farther from the road surface, then the safety and reliability improve, but the routing length and installation complexity increase
Solution Approach 1:
The patent combines both conductor paths within a single external member, allowing the high-voltage path to be positioned higher for safety while maintaining a unified structure that simplifies installation. The merged structure eliminates the need for separate routing and protection of individual paths.
Data Source
AI summary
A wire harness includes a first conductor path having a high priority in protection, a second conductor path having a priority in protection which is lower than that of the first conductor path, and an external member having a tubular shape and accommodating the first conductor path and the second conductor path altogether so as to protect them. The external member has a form in which the first conductor path is positioned farther away from a road surface than the second conductor path within a predetermined range in a longitudinal direction thereof.