Wiring Harness Resistance Detection During Active Load Operation
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Solution Overview
Problem
Existing methods for determining the resistance value of a power distribution wiring harness in vehicles are inefficient, requiring system shutdown and additional hardware, and struggle with accurate resistance measurement in complex electrical systems with varying load states.
Innovation Solution
A method and system for determining resistance values in a power distribution wiring harness by measuring terminal voltages and currents during active and inactive states of electrical loads, using existing sensors and calculating resistance based on a mathematical equation, without the need for dedicated measurement systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dedicated resistance measuring control system is used to determine wiring harness resistance, then measurement precision is improved, but device complexity increases and requires additional hardware
Solution Approach 1:
The existing control system performs multiple functions: it controls electrical loads, monitors system operation, and determines wiring harness resistance using existing sensors. This eliminates the need for dedicated measurement hardware while maintaining measurement capability through software-based calculation using Ohm's law from voltage and current measurements already being taken for other purposes
Solution Approach 2:
The control system uses its own existing infrastructure (sensors, processors, and operational data) to perform resistance measurement without requiring external dedicated measurement equipment. The system serves its own diagnostic needs by leveraging data already being collected during normal operation
2Measurement precision
If the vehicle electrical system is shut down to measure resistance, then measurement precision is improved by eliminating load interference, but productivity decreases due to system downtime
Solution Approach 1:
The measurement approach dynamically adapts to system state by performing resistance calculations during normal operation when loads are active. The control system continuously monitors voltage and current and calculates resistance in real-time, eliminating the need for static shutdown procedures while maintaining measurement validity through mathematical derivation from operational data
Solution Approach 2:
The resistance measurement process occurs continuously during normal system operation rather than requiring intermittent shutdowns. The control system maintains uninterrupted monitoring and calculation of wiring harness resistance, ensuring both continuous diagnostic capability and uninterrupted vehicle operation
3Measurement precision
If additional dedicated measurement hardware is installed to determine resistance, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
Existing sensors and control units are designed to serve multiple purposes: primary control functions and secondary resistance measurement functions. This multi-functionality eliminates the need for additional dedicated measurement hardware, reducing component count and manufacturing costs while maintaining measurement capability
Solution Approach 2:
The existing control system infrastructure serves its own diagnostic needs by using its own sensors and processing capabilities to determine wiring harness resistance. This self-service approach eliminates dependency on external dedicated measurement equipment, reducing overall system cost
4Productivity
If voltage and current measurements are taken during active load operation to determine resistance, then productivity is improved by avoiding system shutdown, but measurement precision may worsen due to load interference
Solution Approach 1:
The control system continuously monitors voltage and current during operation and uses this feedback to calculate resistance in real-time. By continuously comparing measured values against expected operational ranges and using mathematical relationships, the system maintains measurement accuracy despite dynamic load conditions, transforming potential interference into useful diagnostic information
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
Enables swift, accurate, and cost-effective determination of wiring harness resistance, allowing for proactive monitoring and prevention of voltage drops due to aging, ensuring reliable operation of safety-critical components.
Implementation Method 1
calculating the resistance value of the section of the power distribution wiring harness based on the obtained terminal voltage level of the DC voltage source, voltage level of the first electrical load, and electrical current level of the first electrical load
Data Source
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AI summary
A method for determining a resistance value (R Wire_L1) of a section (S) of a power distribution wiring harness (2) connecting a DC voltage source (1) with a first electrical load (L1) and with a second electrical load (L2), wherein a supply current to the first and second electrical loads (L1, L2) is configured to be routed partly through a common electrical conductor of said power distribution wiring harness (2). The method comprises obtaining, during a first detection event in which the first electrical load is in an inactive operating state, terminal voltage level (U_VS_lnactive) of the DC voltage source (1) and voltage level (U_L1_lnactive) of the first electrical load (L1). The method also comprises obtaining, during a second detection event in which the first electrical load (L1) is in an active operating state, terminal voltage level (U_VS_Active) of the DC voltage source (1), the voltage level (U_L1_Active) of the first electrical load (L1) and an electrical current level (I_L1_Active) of the first electrical load (L1). Moreover, the method comprises calculating the resistance value (R Wire_L1) of the section (S) of the power distribution wiring harness (2) that is connecting the DC voltage source (1) with the first electrical load (L1) based on the obtained terminal voltage level (U_VS_lnactive) of the DC voltage source (1) in the inactive operating state; the voltage level (U_L1_lnactive) of the first electrical load (L1) in the inactive operating state; the terminal voltage level (U_VS_Active) of the DC voltage source (1) in the active operating state; the voltage level (U_L1_Active) of the first electrical load (L1) in the active operating state; and the electrical current level (I_L1_Active) of the first electrical load (L1) in the active operating state.