Wireless Control Nodes Replace Vehicle Wire Harnesses

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Solution Overview

Problem

The existing automotive vehicle control systems rely on extensive wire bundles for interconnecting electrical components, which is time-consuming, labor-intensive, and increases vehicle mass, while also causing ergonomic issues and reducing fuel efficiency due to the complexity and weight of connectors and wires.

Innovation Solution

A wireless control system utilizing Bluetooth wireless control nodes to form a virtual network within the vehicle, allowing communication between control nodes and external nodes for controlling vehicle functions, thereby reducing the need for physical wires and connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wire bundles are used to interconnect electrical components, then reliable electrical connections are achieved, but the system complexity and installation time increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidwire bundle complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical wire bundle system with a wireless communication system. Control nodes in each door module communicate with the body control module via wireless signals (e.g., Bluetooth, Wi-Fi, or proprietary wireless protocols), eliminating the need for physical wire connections between door assemblies and the body control module, thereby reducing complexity while maintaining functional reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If extensive wire bundles are routed through the vehicle chassis, then all electrical components are interconnected, but the vehicle mass increases

Engineering Contradiction:

Improvecomponent interconnectionVSAvoidvehicle mass

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

Wireless communication technology replaces the heavy wire bundles and connectors, significantly reducing the mass of the control system. The elimination of extensive wiring harnesses routed through the chassis sheet metal and doors directly reduces vehicle mass while maintaining interconnection functionality through electromagnetic signal transmission

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If in-line connectors are used to interconnect wire bundles, then modular assembly is enabled, but proper seating and optimal connections are difficult to ensure

Engineering Contradiction:

Improvemodular assemblyVSAvoidconnector connection quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent eliminates mechanical connectors entirely by implementing wireless communication between door modules and the body control module. This substitution removes the reliability issues associated with connector seating and connection quality while preserving the modular assembly advantage, as each door module can be independently assembled and installed without complex connector alignment requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If numerous wires and connectors are used, then complete electrical interconnection is achieved, but ergonomic issues and installation difficulty increase

Engineering Contradiction:

Improveelectrical interconnectionVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Wireless communication eliminates the need for manual routing and connection of numerous wires through the chassis and doors, dramatically simplifying the installation process. The system maintains complete electrical interconnection functionality through wireless signal transmission, removing the ergonomic and installation difficulties associated with handling extensive wire bundles and connectors

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Reliability

If wire bundles are routed through the vehicle, then electrical components are interconnected, but the wire mass reduces fuel economy

Engineering Contradiction:

Improveelectrical connectionVSAvoidfuel economy

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces wire bundles with wireless communication systems, eliminating the parasitic mass of extensive wiring harnesses. This mass reduction directly improves fuel economy by reducing the energy required to accelerate and move the vehicle, while maintaining reliable electrical interconnection through electromagnetic communication between control nodes and the body control module

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS7525931B2Wireless multiplex systems and methods for controlling devices in a vehicle

Publication Date: 2009.04.28 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Methods and apparatuses for communicating wireless messages for controlling the functions of devices within a vehicle are provided. The apparatus comprises a first module having a first wireless control node positioned at a first location within the vehicle. The apparatus also includes a second module having a second wireless control node positioned at a second location within the vehicle. Devices are coupled to and controlled by each of the nodes. The first and second nodes are adapted to form a virtual network so that they can communicate the messages to each other for also controlling the devices. The apparatus also has a third wireless node positioned external to the vehicle. The third node is capable of becoming part of the virtual network so that the third node can communicate messages to at least one of the first and the second nodes to further control at least one of the devices.