Wire Harness Power Distribution Standardization
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Solution Overview
Problem
Conventional wire harnesses face issues with short circuits due to exposed conductor portions, which can be triggered by vehicle vibrations, especially when devices are not specified, leading to inconsistent connection parts and reduced flexibility in component usage across different vehicle specifications.
Innovation Solution
A wire harness design featuring a trunk line with power source control boxes distributed across partitions, where a connection unit for a branch wire connects to a sub-power source control box, ensuring power supply to both common and optional devices, with the connection unit housed in a non-flexible casing to prevent contact with the vehicle body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the entire connection part is formed in advance in the electric wire, then the wire harness can be standardized across different vehicle specifications, but the conductor portion becomes exposed which may cause short circuits due to vehicle vibration
Solution Approach 1:
The connection part is divided into two separate components: a connector attached to the electric wire and a corresponding receptacle. This segmentation allows the electric wire to be standardized while the connection parts can be selectively attached or protected, preventing exposed conductors that could cause short circuits.
Solution Approach 2:
A connector serves as an intermediary component between the electric wire and the connection point. This connector includes a conductor and insulating structure that prevents direct exposure of the wire conductor, thereby preventing short circuits while maintaining standardized wire harness design.
2Reliability
If connection parts are formed selectively based on device presence, then short circuits are prevented, but the wire harness cannot be standardized across different vehicle specifications
Solution Approach 1:
The connector is designed as a universal component that can be used across all vehicle specifications. It serves multiple functions: providing electrical connection, preventing short circuits through its insulating structure, and enabling standardized wire harness design while accommodating optional devices through selective attachment.
Solution Approach 2:
The connector is pre-formed with insulating structures and conductor positioning that prevent short circuits before the wire is installed. This preliminary preparation ensures that even if connection parts are formed selectively, the standardized connector design maintains reliability across all applications.
3Ease of operation
If the conductor portion is exposed to enable flexible connection, then ease of connection is improved, but the conductor may contact the vehicle body due to vibration causing short circuits
Solution Approach 1:
The connector includes an insulating structure that acts as a protective shell around the conductor. This insulating layer maintains ease of connection while preventing the conductor from contacting the vehicle body even when vibration occurs, thereby eliminating the short circuit hazard.
Solution Approach 2:
The insulating structure in the connector provides beforehand protection against vibration-induced contact. By designing the connector with built-in insulation and conductor positioning features, the system cushions against the harmful effects of vibration before they can cause short circuits.
Data Source
AI summary
A wire harness includes a trunk line which serves as a transmission line of power from a vehicle battery; and a plurality of power source control boxes which are provided on the trunk line, arranged one by one in each of a plurality of partitions into which a vehicle is partitioned, and distribute the power received through the trunk line to a power-demanding device that demands for supply of power. In at least one partition of the plurality of partitions, the power source control box of the corresponding partition is connected with entire first device arranged in the same partition to supply power among the first device and a second device, and includes a connection unit of a branch wire which is connected to a sub-power source control box that supplies power to the second device.