Vehicle Wiring Harness Modularization via Virtual Layer Clustering
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Solution Overview
Problem
Current wiring harnesses in vehicle electrical systems are deeply meshed, making it difficult to break them down into self-contained modules optimized for automated manufacturing, as central distribution points and complex connections hinder efficient modularization.
Innovation Solution
The method involves moving distributors and control devices to a virtual layer using an algorithm, allowing for clustering and forming Data Power Interfaces (DPIs) that are then connected via a backbone to restore connections, effectively dividing the wiring harness into modularized inner and outer components optimized for automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the wiring harness is designed as a deeply meshed structure to connect all vehicle electrical system entities, then the connectivity and functionality are improved, but the complexity of modularization and automated manufacturing deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the deeply meshed wiring harness into multiple independent modules (e.g., power distribution modules, data communication modules, control unit modules). Each module contains specific connectors and wiring segments that can be manufactured separately through automated processes, then assembled into the complete harness. This resolves the contradiction by maintaining full connectivity functionality while enabling modular manufacturing.
Solution Approach 2:
The patent extracts central distribution points (such as power distribution units and CAN star point couplers) as separate, standardized interface components from the main wiring harness structure. These extracted elements serve as modular building blocks with defined connection interfaces, allowing the remaining harness to be divided into simpler segments that can be manufactured automatically, thus reducing modularization complexity while preserving connectivity.
2Adaptability or versatility
If the wiring harness is designed as a deeply meshed structure with central distribution points, then the functionality and connectivity are improved, but the ease of manufacture deteriorates
Solution Approach 1:
The harness is segmented into standardized modules with uniform connection interfaces, enabling each module to be manufactured independently using automated wiring machines. The segmentation creates discrete manufacturing units that can be produced through repetitive automated processes rather than requiring complex manual assembly of the entire meshed structure.
Solution Approach 2:
The patent performs preliminary design of module interfaces and connection points before manufacturing. Central distribution points are pre-configured as standardized components with defined pin assignments and connection protocols. This preliminary structuring enables automated manufacturing systems to assemble the harness modules without requiring complex real-time decision-making or manual intervention.
3Ease of manufacture
If the wiring harness is divided into modules, then the ease of manufacture and automated production are improved, but the connectivity and integration complexity worsen
Solution Approach 1:
The patent implements universal standardized interfaces for all module connections, where each module type uses common connector designs, pin assignments, and communication protocols. This universality allows different modules to be integrated interchangeably through automated processes, reducing integration complexity despite the increased number of modules. The standardized interfaces serve multiple functions including electrical connection, mechanical coupling, and signal routing.
Data Source
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AI summary
The disclosure relates to a method for unbundling an electrical wiring harness with a plurality of electrical connectors for connecting vehicle electrical system entities according to a connection characteristic, wherein the method comprises: removing the connectors of a first vehicle electrical system entity from the connection characteristic to create a reduced connection characteristic without the removed connectors and an auxiliary connection characteristic with the removed connectors; dividing the connectors of the reduced connection characteristic into a plurality of wiring harness modules of an outer wiring harness; determining clusters of connectors in the auxiliary connection characteristic; forming a connection entity for each cluster to connect the connectors of the respective cluster;Connecting the connection entities of the clusters to each other to form an inner wiring harness; and forming manufacturing modules based on the plurality of wiring harness modules of the outer wiring harness and the connection entities of the inner wiring harness.