Wire Harness Branch Layout to Minimize Overlap Height
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Solution Overview
Problem
In vehicle wire harnesses, particularly those routed in narrow spaces like the bottom surface of battery packs, the height of overlapping portions between combined harnesses becomes an obstacle, preventing smooth routing due to level differences generated by overlapping electric wire bundles.
Innovation Solution
A wire harness configuration where a first harness and a second harness with a trunk line and branch lines are combined and bound at a branch portion, with the first harness extending across the base end of one branch line and bound with a binding material near the branch portion, minimizing the overlapping height and maintaining a stable form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple harnesses are combined by overlapping electric wire bundles, then the wire harness can be formed with extended terminals, but the overlapping portion generates level differences that increase the height of the branch portion
Solution Approach 1:
The patent transitions from vertical stacking (height direction) to horizontal arrangement (width direction) by having the first harness extend across and bind with branch lines in a juxtaposed state rather than stacking them vertically, thereby reducing overlapping height while maintaining terminal extension capability
Solution Approach 2:
The patent segments the binding process into specific locations: binding the first harness with one branch line at a first location, and with another branch line at a second location, creating multiple binding points that distribute and minimize overall overlapping height
2Adaptability or versatility
If the wire harness is routed in the narrow space of the battery pack bottom surface, then the wire harness can connect battery cells to the voltage measurement device, but the height of the overlapping portion becomes an obstacle preventing routing
Solution Approach 1:
The patent resolves the routing obstacle by changing the arrangement from vertical stacking to horizontal juxtaposition, reducing the height dimension to fit within the narrow battery pack space while maintaining all necessary connectivity functions
Solution Approach 2:
The patent applies different binding configurations at different locations along the harness: specific binding points are created where the first harness binds with individual branch lines, optimizing the local structure to minimize height at critical overlapping portions
Data Source
AI summary
A wire harness includes a first harness and a second harness having a plurality of branch lines. The first harness and the second harness are combined and bound, and each of terminals of the first harness and the second harness is extended radially. Exteriors of the first harness and the second harness are removed within a combination range of the first harness and the second harness. The first harness extends across near a base end of one branch line of the second harness, and is bound with a tape near a branch portion together with a vicinity of a base end of another branch line in a juxtaposed state.