Wire Harness Segmentation for Hybrid Vehicle Noise Isolation
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Solution Overview
Problem
High voltage wire harnesses in hybrid vehicles require shielded wires to prevent electromagnetic noise interference with low voltage wires, leading to increased cost, weight, and diameter of the wire harness due to the use of shielded wires.
Innovation Solution
A wire harness design where high voltage wires are passed through a shielding metal pipe, and low voltage wires are placed outside the pipe with a shape-retaining conductor encased in an insulating member, eliminating the need for shielded wires and using clamps with engagement pawls for secure attachment to the vehicle body without fastening members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If shielded wires are used to prevent electromagnetic noise interference with low voltage wires, then electromagnetic noise protection is improved, but cost, weight, and diameter of the wire harness increase
Solution Approach 1:
The wire harness is segmented into two separate routing paths: high voltage wires pass through a metal pipe while low voltage wires are routed outside the pipe. This spatial segmentation eliminates electromagnetic noise interference without requiring expensive shielded wires, thereby reducing weight and cost while maintaining protection against harmful electromagnetic effects.
2Object-affected harmful factors
If shielded wires are used to prevent electromagnetic noise interference, then electromagnetic noise protection is improved, but the diameter of the wire harness increases
Solution Approach 1:
The wire harness is segmented into two separate routing paths: high voltage wires pass through a metal pipe while low voltage wires are routed outside the pipe. This spatial segmentation eliminates electromagnetic noise interference without requiring expensive shielded wires, thereby reducing weight and cost while maintaining protection against harmful electromagnetic effects.
3Object-affected harmful factors
If high voltage wires are passed through a metal pipe for shielding and shape retention, then electromagnetic noise blocking and shape maintenance are improved, but the pipe diameter increases when low voltage shielded wires are used
Solution Approach 1:
The low voltage wires are extracted from the metal pipe and routed separately outside the pipe. This eliminates the need for shielded low voltage wires, thereby reducing the required pipe diameter while maintaining electromagnetic noise blocking for the high voltage wires. The high voltage wires retain their shielding and shape retention benefits within the pipe, while the low voltage wires follow a separate, simpler path.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration prevents electromagnetic noise interference between high and low voltage wires, reduces the wire harness diameter, minimizes weight and cost, and protects the low voltage wire from ground contact by positioning the pipe lower than the wire.
Implementation Method 1
a high voltage wire that is passed through a pipe having shielding properties
Data Source
AI summary
A wire harness capable of combining low voltage wires and high-voltage wires without using shielded wires. The harness is provided with high-voltage wires, which are passed through a pipe possessing shielding properties and shape retention properties, and a low voltage wire, in which a shape-retaining conductor that runs parallel to the pipe and possesses electrically conductive properties and shape retention properties is encased by an insulating member. The low voltage wire is placed on the outside of the pipe and, as a result, the low voltage wire is not affected by the electromagnetic noise of the high voltage wires, which makes it possible to combine the high-voltage wires and the low voltage wire.