This content is not included in your SAE MOBILUS subscription, or you are not logged in.
NEXT GENERATION POWER DISTRIBUTION UNIT IN WIRING HARNESS
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on November 21, 2019 by SAE International in United States
Event: NuGen Summit
Keywords – Miniaturization, Low Profile (LP) Relays, Low Profile (LP) Fuses, Fuse box, Wiring Harness Research and/or Engineering Questions/Objective With the exponential advancement in technological features of automobile’s EE architecture, designing of power distribution unit becomes complex and challenging. Due to the increase in the number of features, the overall weight of power distribution unit increases and thereby affecting the overall system cost and fuel economy. The scope of this document is to scale down the weight and space of the power distribution unit without compromising with the current performance. Methodology Miniaturization involves replacing the mini fuses and J-case fuses with LP mini and LP J-case fuses respectively. The transition doesn’t involve any tooling modification and hence saves the tooling cost. Furthermore, to address stringent weight and space targets, LP mini fuses and LP J-case fuses were further replaced with micro-2 fuse and M-case fuse respectively. Similarly, micro relay and mini relay were replaced with Ultra micro and High current micro relay respectively. Results We took MPV segment vehicle for our initial testing and validation and it has been observed to have 23% reduction in plastic weight, 51% reduction in relay weight, which has consecutively led to significant overall cost reduction. Along with cost and weight, packaging space optimization is yet another advantage. Limitations of this study The tool development for the proposed miniaturized components is at very early stage and therefore the cost is high due to low production level. Also, the lead development time is proportionally higher. What does the paper offer that is new in the field including in comparison to other work by the authors? This paper discusses the effectiveness of the latest technologies in the domain of power distribution system. These technologies have been validated and successfully implemented in several current platforms of Mahindra and Mahindra and have shown significant cost, weight and space benefits to the organization. Conclusions Conclusively, this paper successfully unveils and constructs future opportunities for exploring weight and cost reduction and space optimization in the domain of power distribution system of any automobile architecture. To design optimal power distribution layout in Mahindra and Mahindra, the same strategy is being deployed in new vehicle models as well.