Vehicle Wire Harness Layout for Drive Unit Swing Margin
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Solution Overview
Problem
The challenge of providing a margin in the length of a wire harness, particularly on the vehicle rear side with limited space, is exacerbated by the increasing size of batteries in electric vehicles, making it difficult to accommodate the swinging of the drive unit and inverter device.
Innovation Solution
The wire harness is routed in the vehicle width direction, with one end connected to the inverter device from the side surface and the other end to the battery unit from the rear end, forming an S-shape to provide a margin in the lateral direction, and is covered with a protector and cushioning material to manage stress and swinging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire harness is routed in the front-rear direction of the vehicle, then the layout is simple, but it is difficult to provide a margin in harness length due to small space near rear wheels
Solution Approach 1:
The wire harness routing direction is changed from the front-rear direction to the vehicle width direction. This dimensional change allows the harness to utilize the lateral space between the drive unit and battery unit, providing sufficient length margin while maintaining routing simplicity.
2Duration of action of moving object
If the battery unit is disposed over the entire underfloor portion, then the cruising distance is extended, but the layout space near rear wheels becomes small
Solution Approach 1:
The wire harness routing direction is changed from the front-rear direction to the vehicle width direction. This dimensional change allows the harness to utilize the lateral space between the drive unit and battery unit, providing sufficient length margin while maintaining routing simplicity.
3Area of stationary object
If the drive unit and battery unit are disposed close to each other, then the space utilization is improved, but the wire harness stress increases when drive unit swings
Solution Approach 1:
The wire harness routing direction is changed from the front-rear direction to the vehicle width direction. This dimensional change allows the harness to utilize the lateral space between the drive unit and battery unit, providing sufficient length margin while maintaining routing simplicity.
Solution Approach 2:
The wire harness routing path is changed to include an S-shaped configuration with increased length margin. This parameter change in the harness path allows it to accommodate the swinging motion of the drive unit without excessive stress, while the drive unit and battery unit remain disposed close to each other for space utilization.
Data Source
AI summary
A wire harness mounting structure is provided for a vehicle including a drive unit and a battery unit configured to supply electric power to the drive unit via a wire harness. The drive unit includes a drive motor configured to drive a drive wheel, and an inverter device configured to convert the electric power from the battery unit and supply the converted electric power to the drive motor. One end of the wire harness is coupled to the inverter device from a first direction in a vehicle width direction via an inverter-side connector at a side surface portion of the inverter device, and the other end of the wire harness is coupled to the battery unit from a second direction opposite to the first direction via a battery-side connector at a rear end portion of the battery unit.