Wire Harness Connection Unit Circuit Network Adaptability
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Solution Overview
Problem
The increasing complexity of vehicle electrical systems due to advanced IT applications and diverse customer preferences leads to a significant increase in the number of types of sub-harnesses required for wire harness systems, complicating assembly and reducing work efficiency.
Innovation Solution
A wire harness system with a standard sub-harness and optional sub-harness, where the optional sub-harness is branched from a trunk line and connected to a connection unit with a circuit network, allowing for easy connection or disconnection and switching of selection circuit lines, simplifying the configuration and reducing the number of types needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of types of sub-harnesses is increased to cope with diverse vehicle specifications and optional equipment, then the adaptability to different vehicle configurations is improved, but the device complexity and assembly difficulty increase significantly
Solution Approach 1:
The patent applies universality by designing a standardized sub-harness structure with universal connectors and terminal arrangements that can accommodate multiple vehicle specifications and optional equipment configurations. The sub-harness is designed with standardized circuit board layouts and connector positions that allow it to serve multiple functions across different vehicle types, reducing the need for numerous specialized harness variants.
Solution Approach 2:
The wire harness system is segmented into modular sub-harness units with standardized interfaces. Each sub-harness is divided into functional modules (power supply, signal, communication, ground lines) that can be independently configured and connected. This segmentation allows flexible assembly to meet different vehicle specifications without increasing overall system complexity.
2Adaptability or versatility
If branches are added to sub-harnesses to accommodate various circuit line requirements, then the adaptability to different electrical components is improved, but the shape complexity and manufacturing difficulty increase
Solution Approach 1:
The patent resolves shape complexity by transitioning from two-dimensional planar circuit board designs to three-dimensional spatial arrangements. Connectors and terminals are positioned in multiple layers and depths, allowing circuit lines to route through vertical and lateral dimensions rather than requiring complex lateral branches. This dimensional approach enables adaptable connectivity while maintaining simple, compact sub-harness shapes.
3Adaptability or versatility
If the number of types of optional sub-harnesses is increased to meet diverse customer preferences, then the versatility for customer requirements is improved, but the productivity and work efficiency decrease
Solution Approach 1:
The patent applies preliminary action by pre-configuring standardized terminal arrangements, connector positions, and circuit board layouts in the sub-harness design phase. Optional equipment connections are prepared with predetermined routing paths and standardized interfaces. This preliminary preparation enables rapid assembly and configuration during installation, significantly improving productivity while maintaining versatility for different customer requirements.
4Ease of manufacture
If circuit lines are bundled into multiple sub-harnesses to operate drive systems and optional equipment, then the functional organization is improved, but the quantity of parts and assembly complexity increase
Solution Approach 1:
The patent merges multiple circuit line functions (power supply, ground, signal, communication) into integrated sub-harness units with standardized connectors. Rather than separating circuits into numerous specialized harnesses, the design combines them into unified modules that maintain functional organization through internal circuit board routing. This merging reduces the total number of sub-harnesses required while preserving ease of manufacture through standardized assembly processes.
Data Source
AI summary
A wire harness system having a wire harness and a connection unit is provided. The connection unit includes a circuit network configuring a part of circuit lines for realizing selectively added specification in the wire harness. Selection circuit lines of an optional sub-harness branched from the trunk line of the wire harness are connected to the circuit network of the connection unit. Thus, connection or disconnection between the selection circuit lines and switching of connection among branches or the like of the selection circuit lines can be easily realized by changing the circuit network of the connection unit.