Failure Rate Calculation for Wire Harness Connectors
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Solution Overview
Problem
In complex wiring systems with numerous harnesses and terminal devices, it is difficult to verify the correctness of wire connections and ensure wiring safety due to the complexity of spread-out wiring diagrams.
Innovation Solution
A device that calculates the failure rate of a wire harness by associating electrical wire and connector information with failure rate factors, allowing for easy validation of wiring designs and identification of high-risk areas within the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wiring diagrams are spread over multiple sheets to represent complex wiring systems, then the system can accommodate large numbers of harnesses and terminal devices, but it becomes difficult to check the validity of connection routes and confirm wiring safety
Solution Approach 1:
The patent segments the complex wiring information into discrete electrical wire units, each with unique identification. Instead of presenting the entire wiring diagram across multiple sheets, the system divides the wiring system into individual wire segments that can be checked independently, making it easier to verify connection routes even in large-scale systems
Solution Approach 2:
The patent creates a digital representation (copy) of the wiring system that can be processed and analyzed computationally. By storing wiring connection information in a structured data format, the system enables automated checking of connection validity without requiring manual review of physical diagrams, thus solving the difficulty of detecting connection routes in complex systems
2Productivity
If manual checking methods are used to verify wiring connections, then no additional calculation resources are needed, but the efficiency and accuracy of failure rate calculation are insufficient
Solution Approach 1:
The patent replaces manual mechanical checking methods with automated computational processing. By using a processor to automatically retrieve wiring connection information from storage, calculate failure rates based on stored data, and generate results, the system significantly improves both the efficiency and accuracy of failure rate calculations compared to manual methods
Solution Approach 2:
The patent implements a systematic feedback mechanism where the calculated failure rate information is returned and can be used to identify high-risk wiring areas. This feedback loop enables continuous improvement of wiring design by providing quantitative data that can be analyzed and acted upon to reduce failure rates
3Measurement precision
If detailed tracking of each electrical wire and connector is implemented, then the accuracy of failure rate calculation is improved, but the complexity of data management increases
Solution Approach 1:
The patent creates a universal data structure and processing system that can handle various types of wiring configurations through a single integrated approach. The storage unit stores standardized wiring connection information that can represent different wiring scenarios, and the processing methods are general enough to calculate failure rates for any wiring system, reducing the need for separate complex management systems for different cases
Data Source
AI summary
A failure rate calculation device calculates the failure rate of a wire harness of which each of a plurality of electrical wires is connected with connectors via relay points, the device including: a storage unit which stores electrical wire-connector connection information in which each of the plurality of electrical wires and the connectors are associated with each other and in which type information on each of the electrical wires and type information on each of the connectors are associated with each other, and failure rate information in which the type information belonging to the electrical wire-connector connection information and failure rate factors, associated with the type information, are associated with each other; and a processing unit which, when the wire harness is specified, checks the electrical wire-connector connection information and the failure rate information against each other and calculates a failure rate in the wire harness.