Browse Topic: Cable and wire harness
The integration of Advanced Driver Assistance Systems (ADAS) into modern vehicles necessitates innovative solutions for interior packaging that balance out safety, performance, and ergonomic considerations. This paper introduces an inverted U-shaped steel tube cross car beam (CCB) as a superior alternative to traditional straight tube designs, tailored for premium vehicle instrument panels. The U-shaped geometry overcomes the limitations of straight tube beams by creating additional packaging space for components such as AR-HUDs, steering columns, HVAC systems, and electronic control units (ECUs). This geometry supports efficient crunch packaging while accommodating ergonomic requirements like H-point, eyeball trajectory, and cockpit depth for optimal ADAS component placement. The vertical alignment of the steering column within the U-shaped design further enhances space utilization and structural integrity. This study demonstrates that the inverted U-shaped CCB is a transformative
The integration of hydrogen (H2) as a fuel source in internal combustion engines (ICE) necessitates stringent design measures to mitigate leakage risks and ensure operational safety. This study focuses on the design optimization of vanity cover for hydrogen engines. Computational fluid dynamics (CFD) analysis is carried out to assess and control hydrogen leakage through fuel rail connections, injector interfaces and associated high pressure fuel system components. Detailed modelling of hydrogen flow behavior, diffusion characteristics of leaked hydrogen are simulated for worst case scenarios. Design iterations targeted improvement in ventilation pathways, strategic placement of vent holes, and internal flow management to minimize localized hydrogen buildup. The final design achieved hydrogen concentration, which was less than 4% satisfying the Product safety Hazard Analysis (PSHA) threshold for hydrogen engines. This paper validates the critical role of CFD driven design methodology in
The fuses identification in power distribution boxes, which demands gathering and synthesizing information from diverse sources, represents a significant time consumption for engineers. Furthermore, the inherently repetitive nature of this manual task renders it susceptible to inaccuracies. To address this limitation, this paper examines the application of Large Language Models (LLMs) in the form of chat-bots for analyzing and optimizing vehicular Electrical Distribution Systems (EDS). The research investigates the capabilities of such a system to process complex EDS data, using Vehicle Manual Owner as a study case, with the goal of identifying optimization opportunities and improving project efficiency. The results of the application of Retriever Augmented Generation (RAG) enhanced the model’s ability to handle domain-specific data and function as a specialist assistant for Power Distribution Boxes. Experiments suggest this automated approach can generate valuable insights, such as
Modern vehicle integration has become exponentially more difficult due to the complicated structure of designing wiring harnesses for multiple variants that have diverse design iterations and requirements. This paper proposes an AI-driven solution for addressing variant complexity. By using Convolutional Networks and Deep Neural Networks (CNN & DNN) to generate harness routing using defined specifications and constraints, the proposed solution uses minimal human intervention, substantially less time, and enables less complexity in designing. AI trained modelled systems can generally even predict failures in production methods which also reduces downtime and increases productivity. The new AI system automatically converts design specifications to manufacturable design specifications to avoid confusion with design parameters, by optimizing concepts with connector placements, grommet fittings, clip alignments, and other tasks. The solution coping with the inherent dynamic complexity of
For years the NVH community has known that openings in the dash sheet metal, such as holes to pass wire harnesses through, creates an acoustical weak point that limits the potential noise reduction of the dash insulation system. These pass-throughs can also be a source of water leaks into the vehicle’s interior. With internal combustion engines and now electric inverter power plants generating significant high frequency sound, the need to seal this area is vital. By molding a lightweight barrier that draws through the fiber/absorber interior decoupler and dash sheet metal which mates to a secondary seal molded into an outer engine dash decoupler, the two opposing molded barriers meet in the engine compartment and compress together forming a seal around the wire harness. This male/female molded seal replaces the conventional snap in grommet and eliminates noise/water leaks. The system Sound Transmission Loss (STL) is equivalent to similarly insulated sheet metal with no holes
This ARP specifies the recommended methods of marking electrical wiring and harnesses to aid in the positioning/routing of electrical wiring, harnesses and cable assemblies.
This document defines cables that are used to provide electrical power for U.S. Department of Defense avionics support and test equipment.
This SAE Aerospace Recommended Practice (ARP) provides recommended use and installation procedures for bonded cable harness supports.
The automotive PowerNet is in the middle of a major transformation. The main drivers are steadily increasing power demand, availability requirements, and complexity and cost. These factors result in a wide variety of possible future PowerNet topologies. The increasing power demand is, among other factors, caused by the progressive electrification of formerly mechanical components and a constantly increasing number of comfort and safety loads. This leads to a steady increase in installed electrical power. X-by-wire systems1 and autonomous driving functions result in higher availability requirements. As a result, the power supply of all safety-critical loads must always be kept sufficiently stable. To reduce costs and increase reliability, the car manufacturers aim to reduce the complexity of the PowerNet system, including the wiring harness and the controller network. The wiring harness e.g., is currently one of the most expensive parts of modern cars. These challenges are met with a
The modern automotive industry field is in the middle of a major transformation of the Electric/Electronics (E/E) system design, to meet the future mobility trends driven by Autonomy, Electrification and expanded Connectivity. For these reasons, the ongoing industry trend is to move to more centralized E/E architectures by combining and integrating sub-systems and controllers, from either a functional domain standpoint (horizontal integration, or “cross-domain controllers”) or a geographical zone standpoint (vertical integration, or “central brain with zones”), with the objective to optimize cost, weight, power distribution, provide enhanced security and versatility. This is because electrification, autonomy and connectivity features are significantly increasing the demand for data processing bandwidth, network throughput, intelligent power distribution and wiring harness capabilities for additional sensors/actuators. The evolution to a Centralized Architecture is made possible with
Plastic design is one of the upcoming fields of interest when it comes to weight optimization, sustainability, strength, and overall aesthetics of an automobile. What is often ignored is the amount of flexibility a plastic designer has, of integrating and packaging various components of an automobile into a single part and still make it an integral part of its complex aesthetics. This paper highlights upon one such part that is being developed: An integrated bracket which packages ADAS camera, Rain Light Sensor, and an Auto-dimming IRVM. Apart from packaging the mentioned components, this bracket also has mounting provisions for an aesthetic cover (also referred to as beauty cover). The objective of this paper is to highlight the importance of integration of several parts into a single part for packaging multiple components that need to be placed in a close proximity with each other. This paper includes the demonstration of old design which consisted of multiple parts along with how we
The subsystem of front of dash (FOD) and instrument panel (IP) is a critical path to isolate the powertrain noise and road noise for vehicles. This subsystem mainly consists of sheet metal, dash mats, IP, and the components inside IP such as HVAC and wiring harness. To achieve certain level of cabin quietness, the sound transmission loss performance of this subsystem is usually used as a quantifier. In this paper, the sound transmission loss through the FOD and IP is investigated up to 10kHz, through both acoustic testing and numerical simulation. In the acoustic testing, the subsystem is cut from a vehicle and installed on the wall of two-rooms STL testing suite, with source room being reverberant and receiver room being anechoic. In the testing, various scenarios are measured to understand the contributions from different components. The numerical simulation is based on statistical energy analysis (SEA) because deterministic methods have difficulty to predict the STL up to 10k Hz due
This paper presents the development of a tool for automatic analysis and evaluation of vehicle electrical and electronic systems projects based on data science, in order to detect and suggest optimization opportunities related to cost, weight and efficiency of the electrical distribution circuits of developed or under development projects. On the cost side of vehicular electrical distribution cabling, the project has the potential to bring a great financial return, as it is not uncommon for the responsible company, be it the supplier or Original Equipment Manufacturer (OEM), to err on the side of caution and oversize the project. This approach is often taken as a preventive measure to mitigate any potential design problems that may arise from a leaner design. Considering all challenges inherent to harness development process as electrical harnesses manufacturing complexity and the material amount that is often oversized in design, respecting all the development phases, it is
RF cable assemblies might appear to be a minor component in system design, but they can make all the difference between success and failure, especially in mission-critical industries such as defense and space. The RF interconnect is the vital bridge between many critical systems, including payload, communications, signal transport, and processing. This article will primarily focus on hypersonic missile systems and satellites to illustrate these concepts, as they jointly highlight the importance of RF cable assembly design in extreme environments.
An automotive wiring harness is the backbone of the electrical architecture, and it runs throughout the vehicle to transmit electric power. In a virtual simulation, the mechanical properties of individual strands cannot be considered for the harness bundle (or) cable. Predicting the mechanical properties of electrical cables is a challenging task, and it has major setbacks in virtual simulation. This paper proposes an approach to find out the mechanical properties of an electrical cable and explains how the values are used in virtual simulation. Cable modelling is represented as a lumped mass (or) modelled with a 1D element in the conventional FE modelling approach. In the first part of the study, finite element modelling and material modelling procedures of high and low-voltage electrical cables routed through brackets and troughs are discussed. Mechanical properties are developed using an inverse stiffness characterization method from bench level physical testing in static and
This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into. Clips are typically inserted into sheet or rolled metal
With the spread of new trends such as autonomous driving and vehicle subscription service, drivers may pay less attention to the maintenance of the vehicle. Brake pads being safety critical components, the wear condition of all service brakes is required by regulation to be indicated by either acoustic of optical devices or a means of visually checking the degree of brake lining wear [1]. Current application of the wear indicator in the market uses either sound generating metal strip or wire harness based pad wear sensor. The former is not effective in generating clear alarm to the driver, and the latter is not cost effective, and there is a need for more effective and low cost solution. In this paper, a pad wear monitoring system using MOC(Motor On Caliper) EPB(Electric Parking Brake) ECU is proposed. An MOC EPB is equipped with a motor, geartrain and an ECU. The motor current when applying the parking brake is influenced by the mechanical load at the brake pad side of the system. So
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in high power road vehicle applications that operates at either 20 V to 600 volts regardless of the current applied or any current greater than or equal to 80 A regardless of the voltage applied.. These procedures are applicable only to terminals used for In-Line, Header, and Device Connectors and for cable sizes up to 120 mm2 (4/0). In cases where power levels are mixed in the same connector, (i.e. sensing or normal 14.5 volt system circuits with High Power Contacts) the High Power Contacts must pass J1742 requirements, and all other contacts must pass SAE J2223-2 requirements. The connection system (housing and high power contacts) shall meet J1742 requirements. The requirements and procedures in this document are not intended for
With the significant amount of automation and electrification paving the way for the future of automobiles, the complexity and design of the electrical harnesses have evolved to a point where a minuscule discontinuity can cease the operation of a mechanically pristine vehicle. A vehicle equipped with the best-in-class systems does not always guarantee everlasting operations every time. The wiring harness of any vehicle by its design aspect is one of the most crucial and vulnerable components. Prone to succumbing to factors such as electrical overloading, physical impact, unprofessional handling, and even sabotage, presently there lies no backup system to compensate for the loss of functions of the main electrical network in the event of a failure. In the interest of rapid re-instating of primary functions in a vehicle to make it operational in the event of an electrical failure, the concept of an emergency piggyback electrical network is delineated. Comprising of the essential routings
This paper deals with designing and development methodology of Automatic Electric Start (AES) system for power tiller, which has horizontal diesel engine as prime mover. Designing of AES system constitutes of designing of Starter Motor, Starter Motor Bracket, Flywheel Ring Gear, Battery, Wire Harness Circuit, Fan Alternator and then development these components as integrated system prototype. Unlike tractor market, AES system are not so common in Indian power tiller market therefore, unprecedented design approach towards design of AES system on power tiller engine has been presented in this paper. An engine without AES system requires of huge amount farmers physical effort for starting whereby farmers fatigue levels are always on higher side due to repeated starting task. AES system on power tiller has made 0 N force requirement to start engine which was approximately 92 N earlier. Design of AES system depends on analysis engine cranking torque, which is a complex process and involves
From the perspective of the three elements of electromagnetic interference, the main function of shielding is to cut off the propagation path of electromagnetic noise. The battery pack casing can be regarded as shielding the electromagnetic interference conducted on its internal and external wiring harnesses, but because the battery pack casing has power lines in and out, the battery pack casing is an incomplete shield. In the field of electromagnetics, shielding can be divided into electrical shielding, magnetic shielding and electromagnetic shielding. Therefore, this paper studies its influence on the electromagnetic radiation emission of the whole vehicle from the perspective of shielding mechanism. Due to the role of the switch components in the power battery system, strong current fluctuation di/dt and voltage fluctuation dv/dt will be generated on the power cable, and these interferences will have an important impact on the radiation emission of the vehicle. This paper analyzes
Powertrain wiring cable is a backbone of the electrical architecture in any vehicle electrical system design. The weight of a wiring cable is increasing year by year because of the recent development on high-voltage wiring systems, hybrid electric vehicles (HEVs) and electric vehicles (EVs). Clip failure, loosening clip and terminal breakage under engine roll condition is a common issue in powertrain electric cable (or body harness routing) development cycle in automotive industry. Usage of more number of clips in cable routing results in the powertrain design being more complex and it increases manufacturing cost. The standard procedure practiced to develop any dynamic envelope is by using CAD software tools and performing rigid body movements with the help of the motion file. However, the limitation of this procedure is that it could not be applied to cables, hoses or any component that experiences partial movement (i.e. components connected between body/frame and engine/other moving
This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into. Clips are typically inserted into sheet or rolled metal
This document describes the assembly force guidelines for manually seated push-pins, clips, and similar retention devices. For the purpose of this document, the term “clip” is used to reference all retention devices addressed within this document. Applicable retention devices must have force exerted directly to the clip using the finger/thumb and are hand seated independent of other fasteners. For a retention device to be manually installed and seated independent of other retention devices, it must be seated fully without any interaction with an adjacent fastener (i.e., multiple PIA clips on the back of a hard trim panel). This standard applies to contact surfaces angled at 90 degrees (±10 degrees) and/or perpendicular from the direction of force insertion. Mechanically installed fasteners (screws, rivets, etc.) are not included in this document. This standard does not apply to extraction/retention forces. Refer to USCAR-44 for additional guidelines for clips attached to wire harnesses
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