DESC:FIELD OF THE INVENTION
The present invention generally relates to a wiring harness structure for an electrical vehicle. More particularly, the invention relates to a wiring harness design structure joining all parts of an electrical vehicle (EVs).
BACKGROUND OF THE INVENTION
In the last twenty years, the development of electric vehicles (EVs) has been accelerated for the purpose of negating fuel efficiency issues and reducing /eliminating CO2 emissions to prevent global warming and depletion of fossil fuels. Due to strict CO2 emission regulation/pollution rules, the electrified vehicles sales have increased. An electric drive train of an electrical vehicle is connected by wiring harnesses to perform power transfer. Wiring harness/wiring assembly is a systematic and integrated arrangement of electrical cables or wires which transmit signals or electrical power and information. Wiring harness is commonly used in automobiles as well as construction machinery. Wire harness is the nervous system of automobiles, consisting of wire and connector assemblies of multiple sizes and shapes. The harness are indispensable in controlling the electronic components, transmitting power and signals to every part of the vehicle. For example, many aircraft, automobiles and spacecraft contain many masses of wires which would stretch over several kilometers if fully extended. By binding the many wires and cables into a cable harness, the wires and cables can be better secured against the adverse effects of vibrations, abrasions, and moisture. The construction of wires in to a bundle optimize the space usage. Conventional electrical vehicles (EVs) are dependent on different wiring harnesses to connect different electrical components. This leads to complicate the internal connection of different electrical components. These wiring harness are messy and leads to short circuit many times. The proposed wiring harness design for electrical vehicle (EV) provides a single wiring harness to connect all ancelleries of the vehicle. It reduces the installation and operating cost of wiring with simple harness architecture.

OBJECT OF THE INVENTION
Object of the present invention is to provide a novel harness structure for electrical two wheelers. The proposed design reduces the complexity between internal connections of different parts of the vehicle.
SUMMARY OF THE INVENTION
The object of the invention is achieved by a wiring harness system for a two wheeler. It has a plurality of connectors, connectable to receptors of all electrical components of the two wheeler and a battery, such that, when the connectors are connected to the receptors and the battery, the wiring harness powers all the electric components of the two wheeler.

Another embodiment of the wiring harness comprises more than one wires running throughout the wiring harness, wherein each of the connectors are connected to one or more wires. This reduces the wiring structure inside the vehicle.

Another embodiment of the wiring harness comprises 5 wires, wherein each of the connectors are connected to one or more wires.

Another embodiment of the wiring harness has wires adapted to transmit 12 volts once powered by the battery. This enables the power supply to the harness system and its components.

Another embodiment of the wiring harness has the connectors which are grouped into four clusters, a first cluster, a second cluster, a third cluster, and a fourth cluster, wherein each of the cluster branches out of the wiring harness at four different locations of the wiring harness. The wiring harness has four clusters where all the wiring structure inside the vehicle is shortened within these four clusters.

Another embodiment of the wiring harness has the first cluster of connectors is adapted to branch out at one end of the wiring harness, while the fourth cluster is adapted to be branched out at another end of the wiring harness.

Another embodiment of the wiring harness has the first cluster comprising connectors for atleast a right switchgear, a left switchgear, an indicator flasher, a speed control unit, a brake power off unit, a headlight turn signaling unit, a meter output unit, instrument cluster unit, left indicator, right indicator, main headlight, power lamp, throttle, ignition switch, horn, USB charging socket, an input battery plug, or Miniature circuit breaker (MCB), or combination thereof, wherein MCB is adapted to stop voltage supply on exceeding the admissible voltage supply.

Another embodiment of the wiring harness has the second cluster comprising connectors for at least a trumpet unit, a bit light unit, an electric door unit, a voltage converter unit, or a charger unit, or combination thereof, wherein the voltage converter is adapted to maintain admissible voltage supply in the wiring harness.

Another embodiment of the wiring harness has the third cluster comprising connectors for at least one or more controllers, wireless remote receiver, antenna, tail lamp, or number plate lamp, or combination thereof, wherein the controller are adapted to control one or more electric components of the two wheeler, and the wireless remote receiver is adapted to receive signals from a remote communication device and adapted to communicate the signals to the controller.

Another embodiment of the wiring harness has the fourth cluster comprising connectors for at least an alarm signal unit, an alarm power supply unit, a power red, a power black, a signal support power outage unit, a tail light unit, a tail light negative pole, or a tail light brown unit, or combination thereof. All the four clusters are connected by main cable of the system.

BRIEF DESCRIPTION OF DRAWINGS
The novel features and characteristics of the disclosure are set forth in the description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:
Figure 1 gives electrical circuit diagram of wiring harness in accordance with an embodiment of the present invention.
Figure 2 shows 3D model of wiring harness.
Figure 3 illustrates the example embodiment of the invention in view of block representation of the structures present in the wiring harness system.

DESCRIPTION
For promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof. The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other, sub-systems, elements, structures, components, additional sub-systems, additional elements, additional structures, or additional components.

Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting. Embodiments of the present invention will be described below in detail with reference to the accompanying figures. In the era of electric vehicles, it is essential to connect different parts of the vehicle through a single harness.

The proposed design reduce the internal wirings in the vehicle which saves their installation as well as operating cost. The figure 1 shows electrical circuit diagram of wiring harness in electrical vehicle specifically two-wheeler. There are various parts in an electrical two-wheeler which is connected through a single wiring harness.

The parts in the wiring harness system includes 1. Main cable 2. Instrument Cluster 3. Left Indicator 4. Right Indicator 5. Main Headlight 6. Pilot Lamp 7. 48-60 -> 12V Converter 8. Indicator Flasher 9. Left Switchgear 10. Right Switchgear 11. Throttle 12. Ignition Switch 13. Horn 14. USB Charging Socket 15. Battery Plug (Input) 16. Miniature Circuit Breaker (MCB) 17. Controller 18. Battery Charging Socket 19. Wireless Remote Receiver 20. Antenna 21. Tail Lamp 22. Number Plate Light 23. Speed Control 24. Brake power off 25. Headlight turn signal 26. Meter Trumpet 27. Bit Light 28. Electric Door 29. Alarm Signal 30. Alarm Power Supply 31. Power red 32. Power Black 33. Signal Support Power Outage Tail Light 34. Tail Light Negative Pole 35. Tail Light Brown

The description of each of the components are given below:
1) Main Cable: Main wiring harness connected to all the ancelleries in Electrical Vehicle (EV) two-wheeler as a whole. The harness is copper cored and is bearing separate connectors and wires as described below.

2) Instrument Cluster: Main instrument cluster of the vehicle, shows the speed, battery level, odometer and safety warnings works from - 12 V power supply to + 60V power supply. This is the instrument cluster is designed to showcase the credentials of the vehicle whilst standing or in motion, owing the specific wiring harness design it is able to display the following:
a) Mode of drive (1- Eco, 2-City, 3- Sport): The same varies the kind of torque available to the end rider based on the drive modes at hand.
b) The speed being executed on display & on ground, to showcase the speed the vehicle is operating currently at i.e anywhere from 00kmph - 99kmph (Kilometer per hour - based on the setup and certification).
c) Ready - This showcase the current status of the vehicle, if the side stand is extended the vehicle does not enter in to ignition i.e ready mode and in drivable state.
d) Battery status: The meter console is designed with the specific wiring harness to read the battery charge status anywhere from 25% to 100% charged. This essentially denotes the SOC i.e the State Of Charge of the battery, installed in the vehicle, very similar to a mobile phone but unlike a petrol / diesel powered vehicle. It displays the fuel currently left in the system which is based on the volumetric liters in the fuel tank.
e) Odometer reading: This is highly dependent on the harness and the readout of the odometer i.e total distance run in Kilometer is dependent on the harness readings and connections.
f) Throttle Symbol: This denotes that the electronic throttle i.e accelerator employed into the harness running on a potentiometer cycle is under need of maintenance or repair. On regular functioning where the throttle is running with normal voltages the same does not reflect on the speedometer.
g) ECU Symbol: This denotes that the Electronic controller unit named the Controller which is employed into the harness running on multiple MOSFETS i.e. metal-oxide semiconductor filed-effect transistor is under need of maintenance or repair. On regular functioning where the controller is running with normal voltages, currents & functions the same does not reflect on the speedometer. The Controller works on 60v.
h) Motor Symbol: This denotes that the Brushless DC Motor i.e the torque inducing motor unit which is employed into the harness running on multiple coils is under need of maintenance or repair. On regular functioning where the motor is running with normal voltages the same does not reflect on the speedometer.
i) Headlight Symbol: This denotes that the main headlight is in ON state.
j) LHS & RHS Indicator: The LHS and RHS indicators light up when the vehicle switches are activated for LHS or RHS indication for turning.

3) Indicator (LH) - It is a bulb that lights up when the Left indicator for turning is switched on via LH switchgear.

4) Indicator (RH) - It is a bulb that lights up when the Right indicator for turning is switched on via LH switchgear.

5) Main Headlight – It has two modes, one mode executable from RHS Switchgear listed above to switch on the pilot lamps, second to switch on the main lamps.

6) Pilot Lamp - This lamp is switched on via the RHS switchgear to illuminate the vehicle presence sans the main lamps.

7) 48-60 -> 12V Converter - The functioning of this device is twofold based on the specific harness design at question. It converts the 48-60V DC circuit to 12V so as to supply the 12V ancillary units listed above with the admissible voltage supply.

8) Indicator Flasher - The sole purpose of this device is to break the circuit every 925m/s (Millisecond) to provide the LH and RH Indicator a break in indication/ illumination.

9) Switchgear (LH) - The purpose of this switchgear is to provide the following human input into the harness to control the following – a) Horn Switch: This switch is a onetime switch integrated into the harness to ensure about pressing of switch by executing the horn as audio feedback. b) Boost mode: This is integrated into the harness executable by a switch to provide additional pickup i.e. no / less current amping based on conditions as mapped into the harness and controller.

10) Switchgear (RH) - The purpose of this switchgear is to provide the following human input into the harness to control the following – a) Headlight x 2 positions: Pilot Lamp on (First Position) + Main headlight on (Second position) b) Horn: This on a single press indicates the horn to beep continuously on single press v/s continued press + continued input / press. c) Reverse Gear: When Reverse Gear is pressed in accordance with the throttle due to the harness design executes a reverse spin on the motor and allowing the rider to reverse the vehicle on motor input i.e without physical push input.

11) Throttle: A potentiometer based input device, runs on 5v owing to the harness and allows for the vehicle to take active inputs to move ahead / backward based on the torque applied to the hand held device. This is like an accelerator, used to vary speed of the vehicle. Also works on 24v.

12) Ignition Switch: The switch which is activated via a key and allows the vehicle to be secure in a switched on state ready for the harness inputs.

13) Horn: Indicates audio play / with a beep if applied.

14) USB Charging Socket: The socket allows all +5 volt Universal Serial Bus (USB) devices to charge via the proprietary harness and converter wiring.

15) Battery Plug (Input): This allows the battery to be connected via a SB 50 (Grey) Anderson Plug accommodating 50A and 600V to connect with a reciprocating unisex plug countered in the battery output terminal.

16) Miniature Circuit Breaker (MCB): This is rated @ 40A peak current and is designed to withdraw any peak voltage/current incase an over current more than specified by the harness design is detected by the wiring harness. This is used as a tripping switch to safe guard the system in case of short circuit. This Works on 60v.

17) Controller: The main control unit or Electronic control module of an ancillary part of the circuit, which is designed to control the entire circuit based on the process of the wiring and the signals provided to it.

18) Battery Charging Socket: A C13 socket based to essentially allow only the input charging voltage and current from the charger designed for the specific harness, controller and battery.

19) Wireless Remote Receiver: A remote receiver designed based on the wiring of the harness to allow remote starting, cutoff, alarm and motor locking based on the input provided. It is used to remotely switch on / off the vehicle without the need of using key for ignition. This works on 60v.

20) Antenna: Allowed into the wiring harness specifically to allow wireless input to start, stop and allow the harness to execute a motor lock condition for anti-theft features.

21) Tail Lamp: Wiring is designed into the harness to execute brake light and indicator functions into the said harness.

22) Number Plate Light: Designed to only provide illuminating function to the rear number plate light, which is integrated into the harness.

23) Speed control : Designed to control the speed of the vehicle.

24) Brake power off – Designed to cut off the motor during braking of the vehicle to save battery power and increase range. This works on 60v.

25) Headlight turn signal – Designed to turns on left right signal.

26) Meter Trumpet – Connected to the horn.

27) Bit Light – Designed to control the day time running lamps.

28) Electric door – Designed for the battery lid opening during charging of the vehicle.

29) Alarm signal – Designed for the Alarm beeper during some mal function of the electric systems. Security alarm of the vehicle which is also called as anti theft device, which buzzes an alarm incase someone attempts to steal the bike. This works on 60v.

30) Alarm power supply – Designed to supply power line for the beeper during the communication of the alarm signal.

31) Power Red – This is the Main 60 V line positive supply.

32) Power Black – This is the Main 60v line negative supply.

33) Signal support power outage Tail light – This is designed to provide Positive 12 V Line for Tail Light.

34) Tail light negative Pole – This is designed to provide Negative 12 Line For Tail Light.
35) Tail light brown – This is designed to ignite the Break Light on applying of break in the vehicle.

Figure 1 illustrates the structure of wiring harness system 100. The wiring harness has a plurality of connectors 102, connectable to receptors of all electrical components of the two wheeler and a battery, such that, when the connectors are connected to the receptors and the battery 125, the wiring harness powers all the electric components of the two wheeler.

The example embodiment of the present invention has 5 wires where each wire is adapted to transmit 12 volts once powered by the battery 125. Full length of the harness is 4 ft and the length of wires in the harness varies from 1-4 4ft. The connectors are grouped into four clusters, a first cluster 101a, a second cluster 101b, a third cluster 101c, and a fourth cluster 101d, wherein each of the cluster branches out of the wiring harness at four different locations of the wiring harness. The first cluster 101a of connectors is adapted 102 to branch out at one end of the wiring harness, while the fourth cluster 101d is adapted to be branched out at another end of the wiring harness.
Below table provides the list of components and the cluster those components belong to and their corresponding voltage it works were tabulated.
Components Cluster VOLTAGE
RIGHTSWITCH 1 12V
LEFTSWITCH 1 12V
FLASHER SPEEDCONTROL 1
1 12V
60V
BRAKEPOWEROFF 1 60V
HEADLIGHTTURNSIGNAL 1 12V
METER TRUMPET 1
2 60V
12V
BIT LIGHT 2 12V
ELECTRICDOOR 2 60V
CONVERTER CHARGING 2
2 60V
60V
CONTROLLER55716P 3 60V
CONTROLLER5578P 3 60V
ALARMSIGNAL ALARMPOWERSUPPLY 4
4 60V
60V
POWERRED 4 60V
POWERBLACK 4 60V
SIGNALSUPPORTPOWEROUTAGE TAILLIGHT 4
4 12V
12V
TAILLIGHTNEGATIVE POLE 4 12V
TAILLIGHTBROWN 4 12V
Main cable 60V
Instrument Cluster 1 60V
Left Indicator 1 60V
Right Indicator 1 60V
Main Headlight 1 12V
Pilot Lamp 1 12V
Throttle 1 12V
Ignition Switch 1 60V
Horn 1 12V
USB Charging Socket 1 60V
Battery Plug (Input) 1 60V
Miniature Circuit Breaker (MCB) 1 60V

The first cluster 101a comprising connectors for atleast a right switchgear 103, a left switchgear 104, an indicator flasher 109, a speed control unit 105, a brake power off unit 110, a headlight turn signaling unit 106, a meter output unit 111, instrument cluster unit 107, left indicator 112, right indicator 113, main headlight 108, power lamp 114, throttle 115, ignition switch 116, horn 117, USB charging socket 118, an input battery plug 119, or Miniature circuit breaker (MCB) 120. The MCB 120 is adapted to stop voltage supply on exceeding the admissible voltage supply.

The second cluster 101b comprising connectors for at least a trumpet unit 121, a bit light unit 122, an electric door unit 123, a voltage converter unit 124, or a charger unit 125. The voltage converter is adapted to maintain admissible voltage supply in the wiring harness.

The third cluster 101c comprising connectors 102 for at least one or more controllers 126, wireless remote receiver 127, antenna 128, tail lamp 129, or number plate lamp 130, or combination thereof, wherein the controller 126 are adapted to control one or more electric components of the two wheeler, and the wireless remote receiver 127 is adapted to receive signals from a remote communication device and adapted to communicate the signals to the controller 126.

The fourth cluster 101d comprising connectors for at least an alarm signal unit 131, an alarm power supply unit 132, a power red 133, a power black 134, a signal support power outage unit 135, a tail light unit 136, a tail light negative pole 137, or a tail light brown unit 138.
All the four clusters are connected via main cable 101.
Figure 2 illustrates the example embodiment of the invention on how the harness holds all the components of the vehicle using connectors.
Figure 3 illustrates the example embodiment of the invention in view of block representation of the structures present in the wiring harness system.
ADVANTAGE OF INVENTION
1. Reduce Installation Cost
2. Reduce Operating cost
3. More efficient
4. Less complex
5. Provide Safety

Claims
1. A wiring harness system 100 for a two wheeler comprising:
a plurality of connectors 102, connectable to receptors of all electrical components of the two wheeler and a battery 125, such that, when the connectors are connected to the receptors and the battery, the wiring harness powers all the electric components of the two wheeler.

2. The system as claimed in claim 1, wherein the wiring harness comprises more than one wires running throughout the wiring harness, wherein each of the connectors are connected to one or more wires.

3. The system as claimed in claim 2, wherein the wiring harness comprises 5 wires, wherein each of the connectors are connected to one or more wires.

4. The system as claimed in claim 2 or 3, wherein each wire is adapted to transmit 12 volts once powered by the battery 125.

5. The system as claimed in claim 2, wherein the connectors 102 are grouped into four clusters, a first cluster 101a, a second cluster 101b, a third cluster 101c, and a fourth cluster 101d, wherein each of the cluster branches out of the wiring harness at four different locations of the wiring harness.

6. The system as claimed in claim 5, wherein the first cluster 101a of connectors is adapted to branch out at one end of the wiring harness, while the fourth cluster 101d is adapted to be branched out at another end of the wiring harness.

7. The system as claimed in claim 5, wherein the first cluster 101a comprising connectors for atleast a right switchgear 103, a left switchgear 104, an indicator flasher 109, a speed control unit 105, a brake power off unit 110, a headlight turn signaling unit 106, a meter output unit 111, instrument cluster unit 107, left indicator 112, right indicator 113, main headlight 108, power lamp 114, throttle 115, ignition switch 116, horn 117, USB charging socket 118, an input battery plug 119, or Miniature circuit breaker (MCB) 120, or combination thereof, wherein MCB is adapted to stop voltage supply on exceeding the admissible voltage supply.

8. The system as claimed in claim 5, wherein the second cluster 101b comprising connectors for at least a trumpet unit 121, a bit light unit 122, an electric door unit 123, a voltage converter unit 124, or a charger unit 125, or combination thereof, wherein the voltage converter is adapted to maintain admissible voltage supply in the wiring harness.

9. The system as claimed in claim 5, wherein the third cluster 101c comprising connectors for at least one or more controllers 126, wireless remote receiver 127, antenna 128, tail lamp 129, or number plate lamp 130, or combination thereof, wherein the controller 126 are adapted to control one or more electric components of the two wheeler, and the wireless remote receiver 127 is adapted to receive signals from a remote communication device and adapted to communicate the signals to the controller 126.

10. The system as claimed in claim 5, wherein the fourth cluster 101d comprising connectors for at least an alarm signal unit 131, an alarm power supply unit 132, a power red 133, a power black 134, a signal support power outage unit 135, a tail light unit 136, a tail light negative pole 137, or a tail light brown unit 138, or combination thereof.

Dated this on 09th March, 2023

GAURAV SINGHAL
IN/PA 1426
AGENT FOR THE APPLICANT

ABSTRACT
WIRING HARNESS DESIGN FOR ELECTRICAL TWO-WHEELER
The present disclosure provides a novel wiring harness design system 100 for electrical vehicle specifically two-wheelers. The electrical circuit diagram of wiring harness in electrical vehicle consists of various individual devices which is connected by single harness to reduce wiring inside the vehicle. The individual devices run in series or parallel to each other and bring best outcome with less wiring. This reduces the overall installation and operating cost of vehicle harness.
FIG 1
,CLAIMS:Claims
1. A wiring harness system 100 for a two wheeler comprising:
a plurality of connectors 102, connectable to receptors of all electrical components of the two wheeler and a battery 125, such that, when the connectors are connected to the receptors and the battery, the wiring harness powers all the electric components of the two wheeler.

2. The system as claimed in claim 1, wherein the wiring harness comprises more than one wires running throughout the wiring harness, wherein each of the connectors are connected to one or more wires.

3. The system as claimed in claim 2, wherein the wiring harness comprises 5 wires, wherein each of the connectors are connected to one or more wires.

4. The system as claimed in claim 2 or 3, wherein each wire is adapted to transmit 12 volts once powered by the battery 125.

5. The system as claimed in claim 2, wherein the connectors 102 are grouped into four clusters, a first cluster 101a, a second cluster 101b, a third cluster 101c, and a fourth cluster 101d, wherein each of the cluster branches out of the wiring harness at four different locations of the wiring harness.

6. The system as claimed in claim 5, wherein the first cluster 101a of connectors is adapted to branch out at one end of the wiring harness, while the fourth cluster 101d is adapted to be branched out at another end of the wiring harness.

7. The system as claimed in claim 5, wherein the first cluster 101a comprising connectors for atleast a right switchgear 103, a left switchgear 104, an indicator flasher 109, a speed control unit 105, a brake power off unit 110, a headlight turn signaling unit 106, a meter output unit 111, instrument cluster unit 107, left indicator 112, right indicator 113, main headlight 108, power lamp 114, throttle 115, ignition switch 116, horn 117, USB charging socket 118, an input battery plug 119, or Miniature circuit breaker (MCB) 120, or combination thereof, wherein MCB is adapted to stop voltage supply on exceeding the admissible voltage supply.

8. The system as claimed in claim 5, wherein the second cluster 101b comprising connectors for at least a trumpet unit 121, a bit light unit 122, an electric door unit 123, a voltage converter unit 124, or a charger unit 125, or combination thereof, wherein the voltage converter is adapted to maintain admissible voltage supply in the wiring harness.

9. The system as claimed in claim 5, wherein the third cluster 101c comprising connectors for at least one or more controllers 126, wireless remote receiver 127, antenna 128, tail lamp 129, or number plate lamp 130, or combination thereof, wherein the controller 126 are adapted to control one or more electric components of the two wheeler, and the wireless remote receiver 127 is adapted to receive signals from a remote communication device and adapted to communicate the signals to the controller 126.

10. The system as claimed in claim 5, wherein the fourth cluster 101d comprising connectors for at least an alarm signal unit 131, an alarm power supply unit 132, a power red 133, a power black 134, a signal support power outage unit 135, a tail light unit 136, a tail light negative pole 137, or a tail light brown unit 138, or combination thereof.

Dated this on 09th March, 2023

GAURAV SINGHAL
IN/PA 1426
AGENT FOR THE APPLICANT