Wire Harness Surge Voltage Suppression via Segmented Shielding
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Solution Overview
Problem
Conventional wire harnesses in hybrid and electric vehicles experience increased surge voltage generation due to impedance mismatches between inverters and motors, leading to ineffective suppression of surge voltages as the harness length increases, causing potential motor damage.
Innovation Solution
A wire harness with multiple surge reducing means, including wire-side, connector-side, and middle portion-side components, utilizing a shield member and magnetic materials to distribute the reduction of surge voltage along the harness length, maintaining a suitable motor input voltage regardless of harness length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the wire harness length is increased to connect inverter and motor, then the connection flexibility is improved, but the surge voltage generation rate increases
Solution Approach 1:
The wire harness is divided into multiple sections with surge reducing means (shield members and magnetic beads) positioned at different locations along the harness. This segmentation allows the long harness to be managed in controlled segments, each contributing to surge voltage reduction while maintaining the overall length needed for connection flexibility.
Solution Approach 2:
Shield members and magnetic beads are introduced as intermediary components within the wire harness. These intermediaries act as surge voltage suppression elements that do not interfere with the electrical signal transmission but effectively reduce surge voltage generation along the harness length.
2Object-generated harmful factors
If a conventional surge voltage suppression circuit is added, then some surge voltage reduction is achieved, but the suppression effect is insufficient for long wire harnesses
Solution Approach 1:
Instead of using a single surge suppression circuit, the invention distributes multiple surge reducing means (shield members and magnetic beads) at different positions along the wire harness. This segmented approach ensures that surge voltage is suppressed at multiple points, making the suppression effective even for long harness lengths where a single suppression point would be insufficient.
Solution Approach 2:
The invention changes the approach from using a conventional electronic suppression circuit to using passive electromagnetic shielding components (shield members and magnetic beads) that physically alter the electromagnetic field distribution along the harness, providing more reliable surge voltage suppression.
3Reliability
If multiple surge reducing means are distributed along the wire harness, then the surge voltage suppression effectiveness is improved, but the device complexity increases
Solution Approach 1:
The shield members and magnetic beads are integrated into the wire harness structure itself rather than being separate added components. This merging of surge protection functionality into the existing harness structure minimizes additional complexity while achieving effective distributed surge voltage suppression.
Solution Approach 2:
The shield members serve multiple functions: they provide electromagnetic shielding, support wire arrangement, and contribute to surge voltage reduction. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity despite the distributed nature of the surge reducing means.
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
Effectively suppresses surge voltage across varying harness lengths, reducing motor input voltage to rated levels, enhancing the durability of the motor and increasing the output and switching speed of the inverter.
Implementation Method 1
a shield member collectively surrounding an outer circumferential side of the wire portion
Implementation Method 2
the connector-side surge reducing means includes a magnetic material
Data Source
AI summary
A wire harness includes a wire portion having three wires arranged in the same direction, connectors connected to both end portions of the wire portion, a middle portion installed in an intermediate position of the wire portion between the connectors, a wire-side surge reducing section provided in the wire portion, a connector-side surge reducing section provided in each of the connectors, and a middle portion-side surge reducing section provided in the middle portion.