Modular Wiring Harness Connectors for Complex Circuit Replacement
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Solution Overview
Problem
The complexity and customization of electrical wiring harnesses in vehicles, such as automobiles, trains, and ships, lead to difficulties in production and maintenance due to their large and intricate nature, requiring specialized equipment and skilled personnel, and existing methods are not suitable for batch production or easy maintenance.
Innovation Solution
A wiring harness module with a conductor portion connected to input and output conductive connectors, allowing for modular assembly and connection of multiple modules to form a combined wiring harness, reducing volume and cost, and enabling flexible and efficient production and maintenance through modular design and automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wiring harnesses are made complex to accommodate increasing electrical functions and circuits, then the electrical functionality is improved, but the production and maintenance difficulty increases
Solution Approach 1:
The wiring harness is divided into multiple independent modules, each containing specific circuits and functions. These modules can be produced separately using standardized processes and assembled through connector interfaces, enabling complex electrical functionality while maintaining production simplicity and facilitating targeted maintenance of only affected modules.
Solution Approach 2:
Standardized connector interfaces and modular designs enable wiring harness modules to be universally applied across different vehicle configurations and electrical systems. The same module types can serve multiple functions or be reconfigured for different applications, reducing the need for custom production equipment and simplifying maintenance through interchangeable components.
2Adaptability or versatility
If wiring harnesses are made large to include all necessary circuits, then the electrical coverage is improved, but the replacement cost and time increase when damaged
Solution Approach 1:
The large wiring harness is segmented into smaller functional modules that can be independently replaced. When damage occurs, only the affected module needs to be replaced rather than the entire harness, significantly reducing replacement time, cost, and inventory requirements while maintaining comprehensive electrical coverage through modular assembly.
Solution Approach 2:
Damaged wiring harness modules can be discarded and replaced with new or refurbished modules. The modular design enables recovery and reuse of undamaged modules from replaced assemblies, reducing waste and lowering overall replacement costs while maintaining full electrical coverage.
3Adaptability or versatility
If wiring harnesses are made flexible to accommodate customization, then the adaptability to different configurations is improved, but the production complexity increases
Solution Approach 1:
The wiring harness is segmented into standardized modules that can be configured in different combinations to meet customization requirements. This modular approach enables flexible adaptation to different vehicle types and configurations while maintaining simple, repeatable production processes for each module type, avoiding the need for complex custom production equipment.
Solution Approach 2:
The modular wiring harness system enables dynamic reconfiguration for different applications by assembling different module combinations. The standardized interfaces and connection protocols allow the same basic modules to be dynamically arranged to meet various customization needs without requiring dedicated production lines for each configuration.
Data Source
AI summary
A wiring harness module and a combined wiring harness, the wiring harness module including a conductor portion and an insulation portion enclosing the conductor portion. The conductor portion includes at least one conductor, each of which is connected to at least one input conductive connector and at least one output conductive connector. An electrical connection of the conductors of different wiring harness modules is realized by connecting the input conductive connector and the output conductive connector of the different wiring harness modules. The combined wiring harness is formed by splicing a plurality of wiring harness modules in accordance with a preset splicing manner, and the conductors of the plurality of wiring harness modules being electrically connected to each other via the input conductive connector and the output conductive connector. In the present disclosure a complex conductive circuit is combined.