DESC:POWER HARNESS ASSEMBLY
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202421020628 filed on 19/03/2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to power connectors. Particularly, the present disclosure relates to a power harness assembly.
BACKGROUND
A power supply wiring harness assembly is an essential component in every electrical system, from automotive and industrial applications to consumer electronics and renewable energy systems. The power supply wiring harness assembly is an organized collection of wires, connectors, and protective elements designed to transmit electrical power and signals efficiently and safely throughout a device or vehicle. The harness assemblies help to streamline the complex network of wires, ensuring that electrical components are properly connected and minimizing the risk of electrical faults, damage, or disorganization. As technology advances, the role of power supply wiring harnesses becomes increasingly vital, especially with the rise of electric vehicles (EVs), smart systems, and more intricate electronics.
Conventionally, a power supply wiring harness assembly is constructed by manually assembling individual wires and components into a cohesive harness structure. Specifically, the wires carrying electrical power or signals are routed through a series of protective tubing or flexible conduit to prevent damage. The wire ends are stripped and pressed with terminals or spliced together using soldering or mechanical connectors to establish secure electrical connections. In many cases, the harness is bundled together using cable ties or clips to keep the wires organized and prevent tangling. The wires are routed to specific locations within the system, such as different components or subassemblies that require power, all without the benefit of overmoulding or covers to protect or secure connectors at either end. Typically, adhesive-backed tapes or heat shrink tubing are used to cover and secure connectors, providing some protection from environmental factors and mechanical stresses.
However, there are certain problems associated with the existing or above-mentioned power supply wiring harness assembly. For instance, without overmoulding, the connectors are exposed to potential damage from moisture, dust, or physical impacts, leading to short circuits or degraded performance. Further, the lack of secured covering ensures that the connections at the load end are securely protected from wear, abrasion, or accidental disconnections, compromising the overall integrity of the wiring assembly. Additionally, without the above-mentioned protective features, the harness is more prone to mechanical stress, vibration, or exposure to extreme temperatures, causing wires to fray, disconnect, or degrade over time. Consequently, the assembly leads to increased maintenance needs, higher failure rates, and reduced lifespan.
Therefore, there exists a need for a power supply wiring harness assembly that is safe, efficient, and overcomes one or more problems as mentioned above.
SUMMARY
An object of the present disclosure is to provide a power harness assembly for automotive solutions.
Another object of the present disclosure is to provide a power harness assembly capable of efficiently and securely transmitting electrical power and signals between components while ensuring safety and reliability.
In accordance with an aspect of the present disclosure, there is provided a power supply wiring harness assembly for connecting a load and a power source, the assembly comprises:
- at least one high-voltage cable comprising a power source end and a load end;
- at least one source side connector; and
- at least one load side connector,
wherein the at least one load side connector is accommodated within a load side cover.
The power supply wiring harness assembly, as described in the present disclosure, is advantageous in terms of providing improved organization, reduced risk of electrical faults, and enhanced durability by securely routing and protecting wires. Specifically, the use of a load side cover and connector overmould enhances the safety by providing additional protection to connectors and wires from environmental factors such as moisture, dust, and physical damage. The overmould creates a secure, moulded seal around connectors, preventing disconnections and ensuring strain relief with minimized vibrations. Consequently, the above-mentioned features contribute to a more reliable, long-lasting power transmission, minimizing maintenance needs and increasing the overall safety and efficiency of the assembly.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figure 1 illustrates a power supply wiring harness assembly, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
As used herein, the terms “power supply wiring harness assembly” and “assembly” are used interchangeably and refer to an assembled group of wires, cables, connectors, and terminals designed to connect various electrical components within an electrical system, typically used in automotive, industrial, or electronic devices. The wiring harness delivers power and signals to ensure organized, safe, and efficient connections, minimizing the risk of electrical faults or damage due to improper connections. Further, the assembly is custom-designed to meet the specific needs of the application, ensuring that each wire is appropriately insulated, routed, and protected to withstand environmental conditions like heat, moisture, and vibration. Furthermore, the types of power supply wiring harness assemblies, include, but not limited to, single-phase, three-phase, and DC harnesses, each suited for different power requirements and systems. The single-phase harnesses are used in residential applications, and three-phase harnesses are designed for industrial and commercial power systems requiring higher efficiency. The method of assembling a power supply wiring harness involves selecting the appropriate gauge and type of wire, cutting and stripping the wires to the correct length, and attaching connectors and terminals to ensure reliable and secure electrical contacts. Subsequently, the harness is tested for functionality and quality, ensuring the industry standards, and is ready for installation in the intended system.
As used herein, the term “load” refers to an electrical device that consumes power from a power source. The load draws current through the wiring harness and is powered by the electrical supply. Further, the capacity and type of load determine the specifications of the wiring harness, including the gauge of wires, connectors, and insulation, to ensure the harness handles the required power without overheating, short-circuiting, or degrading over time. The various types of loads include resistive load, inductive load, and capacitive load. Resistive loads, like heating elements and incandescent bulbs, primarily convert electrical energy into heat or light. Inductive loads, such as motors or transformers, create magnetic fields that may cause voltage spikes and require special wiring considerations. Capacitive loads, often found in electronic circuits, store electrical energy and can affect the power factor of the system. The method for handling these loads within a wiring harness involves calculating the total current required by all connected loads, selecting appropriately rated wires and connectors, and ensuring the assembly includes any necessary components, like fuses or resistors, to protect against overloads or power surges. Testing the harness for continuity and voltage drop is also an important step in ensuring proper load handling.
As used herein, the terms “power source” and “source” are used interchangeably and refer to a source for the origin of the electrical energy that flows through the harness to power various components and loads in the assembly. The power source is a critical part of an electrical circuit design, as it determines the type of power supply required, such as AC (Alternating Current) or DC (Direct Current). Further, the source needs to be properly matched to the electrical components to ensure the system operates within safe limits and maintains optimal performance. The types of power sources include batteries, which are typically used for portable devices or vehicles that require DC power, AC power supplies, which convert household or industrial mains electricity into usable current for larger systems, and solar power systems, which convert sunlight into electrical energy using photovoltaic cells. The method for incorporating a power source into a wiring harness involves selecting the correct type of source based on the application, ensuring proper voltage regulation, and designing the harness to safely route power from the source to the various loads while protecting the system from issues such as voltage spikes or short circuits.
As used herein, the terms “high-voltage cable” and “cable” are used interchangeably and refer to a specialized cable designed to carry electrical power at higher voltages, typically above 1,000 volts. The cables are essential for transferring power in industrial, automotive, and energy systems that require substantial electrical energy. The high-voltage cables are constructed with robust insulation to prevent electrical shock, short circuits, and system failures, ensuring safe operation even under challenging conditions. The cables are engineered to withstand high temperatures, environmental factors such as, but not limited to, moisture and UV exposure, and physical stresses. The types of high-voltage cables used in power supply wiring harness assemblies, include single-core cables, multi-core cables, and shielded cables. The single-core cables are used when only one conductor is needed for power transmission, and multi-core cables are used when multiple conductors are required for distributing power to various components. The shielded cables are used to protect the signal and prevent electromagnetic interference (EMI), especially in systems where high-voltage cables run close to sensitive electronic components. The method of incorporating high-voltage cables in an assembly involves selecting cables with the appropriate voltage rating and insulation type based on the system's requirements, then properly routing and securing the cables to prevent contact with other conductive materials.
As used herein, the term “power source end” refers to a part of the harness that connects directly to the power source, such as a battery, generator, or external power supply. The connection is critical to ensure that the electrical energy is properly transmitted from the source to the rest of the circuit. The power source end typically includes components such as, but not limited to, connectors, terminals, and protective elements. The proper design and secure connections at the power source end are vital to prevent power loss, overheating, or electrical hazards. The types of power source ends depend on the application and the power source being used. For instance, battery terminals are used for systems that rely on DC power from batteries, while AC power plugs or connectors are used for systems powered by alternating current from mains electricity. In some applications, quick-disconnect connectors are used to allow for easy removal and replacement of power sources, especially in systems that require frequent maintenance or swapping of power supplies. Proper insulation and strain relief are also applied to avoid mechanical damage and electrical shorts, ensuring safe and efficient power delivery from the source to the load.
As used herein, the term “load end” refers to a section of the harness that connects to the load, which is the electrical device or component that consumes the power provided by the source. The load end is designed to ensure that electrical energy is safely delivered to the load with the proper voltage, current, and protection. The load end includes components such as, but not limited to, connectors, terminals, resistors, capacitors, or relays, depending on the load's requirements. The proper design of the load end is crucial to ensure that the system operates efficiently and that the load is protected from overcurrent, voltage spikes, or short circuits.
As used herein, the term “source side connector” refers to a connector at the end of the harness that interfaces with the power source, allowing electrical energy to flow from the source to the wiring harness and then to the load. The source side connector plays a crucial role in establishing a secure, reliable connection between the power source (such as a battery, power supply, or generator) and the wiring harness. The types of source side connectors are designed for different applications and power ratings. For instance, blade connectors are commonly used in automotive applications due to their simplicity and ease of use, while circular connectors are typically used in industrial or high-power environments, providing better durability and sealing against environmental factors. The quick-disconnect connectors are used in systems where the power need to be disconnected or replaced frequently. The method for incorporating a source side connector involves selecting the appropriate connector type based on the power source’s voltage and current specifications, ensuring secure connections with proper polarity, and incorporating protective elements.
As used herein, the term “load side connector” refers to a connector at the end of the harness that interfaces with the load. The load side connector serves as the point of connection between the wiring harness and components such as, but not limited to, motors, lights, sensors, or other electrical systems. The load side connector is crucial for delivering the required electrical power to the load in a safe, reliable, and efficient manner. The connector is designed to handle the load’s current and voltage requirements and is equipped with features to ensure a secure connection, prevent accidental disconnections, and protect against electrical faults like short circuits. The types of load side connectors depend on the application and the type of load. The ring terminals and spade connectors are commonly used for automotive or industrial loads for ease of connection and secure attachment. The circular connectors are used in high-power systems for providing robust and durable connections that withstand harsh environments. The Push-in or snap-fit connectors are used in consumer electronics for ease of assembly and disassembly. The method for incorporating a load side connector involves selecting the correct connector type based on the load’s power requirements and ensuring proper insulation, secure connections, and correct polarity.
As used herein, the term “load side cover” refers to a protective component or casing that shields the connectors and wiring at the load side of the harness. The load side cover serves to safeguard the electrical connections from environmental factors such as dust, moisture, and physical damage, ensuring the longevity and reliability of the assembly. The load side cover also provides additional protection from electrical shorts, prevents accidental contact with live terminals, and improves the overall safety of the installation. The types of load side covers are designed for different applications and protection needs. The plastic or rubber covers are commonly used for light-duty applications, offering basic protection against moisture, dust, and impact. The metal or moulded protective covers are used to provide better shielding and resistance to high temperatures or physical wear. The method of using a load side cover involves selecting the appropriate cover based on the environmental conditions and the level of protection required.
As used herein, the term “source side overmould” refers to a protective, moulded casing that covers the connector and wiring at the source side of the harness. The over moulding is made from durable materials such as, but not limited to, rubber, silicone, or plastic, and provides enhanced protection against environmental factors such as moisture, dust, abrasion, and vibrations. The overmoulding secures the individual wires and connectors, ensuring that wires remain in place and are shielded from mechanical damage. Additionally, overmoulds provide strain relief to prevent wires from becoming stressed or damaged at the connection points, which is crucial for maintaining the integrity and longevity of the harness.
As used herein, the term “load side overmould” refers to a protective covering that encases the connectors and wiring at the load side of the harness. The overmoulding is made from durable, flexible materials such as, but not limited to, rubber, silicone, or thermoplastic elastomers (TPE), designed to shield the electrical connections from environmental hazards like moisture, dust, abrasion, and mechanical stress. Further, by providing strain relief and physical protection, the load side overmould ensures that the wiring and connectors remain intact, reducing the risk of wear and tear, short circuits, or disconnections over time. The types of load side overmoulds are based on different materials and designs chosen based on the specific requirements of the application. For instance, the silicone overmoulds are used for high-temperature or chemically environments, and TPE or rubber overmoulds provides flexibility and resistance to environmental factors, making them suitable for general industrial and automotive applications. The method of creating a load side overmould involves placing the connectors and wiring into a mould and then injecting or overmolding the protective material around the components. Once solidified, the overmould helps to simplify installation and maintenance, offering a single, cohesive unit that is easily handled in complex wiring systems.
As used herein, the term “wire openings” refers to the gaps or apertures in the overmoulded casing at the load side of a power supply wiring harness assembly for routing the individual wires or conductors. The openings are critical for ensuring that the wires exit the overmould securely and maintain the proper connection to the load, such as electrical devices or components. The design of the wire openings also plays a role in protecting the wires from external elements, such as moisture or dust, while allowing for the necessary flexibility and movement of the wires during operation or installation.
As used herein, the term “locking slots” refers to the gaps provided for securing the attachment points connecting the connectors or components fastened into the other component. The locking slots help to prevent accidental disconnections or slippage of components, ensuring that the electrical connections remain stable and reliable during operation. The slots are used to secure connectors or cable ties, providing strain relief and improving the durability of the wiring harness, especially in environments with vibration or mechanical stress. The types of locking slots used in load side overmoulds are designed for different applications and connector types. The single-slot designs are commonly used for simple, secure connections, allowing for easy insertion of locking pins or tabs. Multiple-slot designs are used in more complex assemblies where different components need to be locked in place, offering greater flexibility in securing various parts of the harness. The method of incorporating locking slots involves designing the overmould with the appropriate slots during the molding process. The mold is engineered to include the features, ensuring they align with the connectors or components to be secured. After the overmould is injected, cooled, and solidified, the locking slots help maintain the integrity and safety of the wiring harness.
As used herein, the term “rubber sleeve” refers to a protective covering made of flexible rubber material that is applied to wires or cables to provide insulation, prevent abrasion, and protect against environmental factors such as moisture, dust, and chemicals. The rubber sleeve helps to safeguard the integrity of the wiring by providing a cushioning layer that absorbs mechanical stress and prevents wear and tear, especially in high-vibration environments or systems subject to frequent movement. The sleeve also acts as a dielectric insulator, preventing electrical shorts and ensuring the safe operation of the harness. The types of rubber sleeves include standard rubber sleeves, made from materials such as natural rubber or synthetic rubber, offer general protection against abrasion and environmental exposure, heat-resistant rubber sleeves, made from silicone or fluoropolymer compounds. The method of incorporating a rubber sleeve involves selecting the appropriate type of rubber based on the application’s specific requirements, then sliding the sleeve over the wires or cables during the assembly process. The sleeve is typically secured in place with adhesive or mechanical methods to ensure it remains intact, and the overall assembly is tested for proper insulation, durability, and flexibility.
As used herein, the term “connector opening” refers to an aperture or slot in the rubber covering of a wiring harness that allows connectors to pass through or be attached to the wiring. The opening is crucial for ensuring that the connectors, which serve as the interface for electrical components, are properly integrated into the harness while maintaining the protective qualities of the rubber sleeve. The connector opening helps preserve the sleeve’s insulating properties and facilitates the secure attachment of connectors or terminals. The connector opening also serves to protect the electrical connections from environmental factors, such as moisture, dust, and physical damage, which could otherwise interfere with the system’s performance.
As used herein, the term “fastening slots” refers to openings or grooves incorporated into the rubber covering of a wiring harness to hold or secure components such as connectors, cable ties, or other fastening elements in place. The slots ensure that the rubber sleeve remains firmly attached to the wiring harness, preventing slippage or movement of the wires or cables it protects. The fastening slots also help organize and secure the wiring assembly, improving its overall stability and preventing excessive strain on the wires during operation. The inclusion of these slots adds an extra layer of security, particularly in environments where vibration or mechanical stress is present. Multiple slots are used for organizing and securing several components or cables simultaneously, ideal for more complex harness assemblies that include multiple wires or connectors.
As used herein, the term “front surface” refers to the outermost part or face of the protective casing that covers the connectors and wiring at the load side of the harness. The front surface plays a crucial role in providing physical protection and serving as the interface with the external environment. The front surface is designed to shield the electrical connections from contaminants like dust, water, and prevent accidental contact with live terminals. The front surface is designed to provide additional functions, such as mounting points for other components, easy access for maintenance, or even branding and labelling of the assembly. The method of designing and implementing the front surface of a load side cover involves selecting the appropriate material (such as, but not limited to, plastic, rubber, or metal) and forming the cover with features that match the harness's requirements. The cover is typically moulded or injected and, additional seals or gaskets are applied to ensure that the front surface offers full protection against external elements.
As used herein, the term “top surface” refers to the uppermost exterior part of the protective casing that encloses the electrical connections on the load side. The top surface plays a crucial role in protecting the components from external elements like moisture, dust, and physical damage. The top surface is also designed for easy access to the load connections or feature mounting points for additional components. The top surface's shape and material are selected to provide durability, flexibility, and heat resistance depending on the specific needs of the wiring harness assembly.
As used herein, the term “cover opening” refers to an aperture or gap located on the uppermost part of the load side cover. The cover opening allows access to the electrical components, connectors, or cables that are housed within the cover, facilitating the connection and disconnection of the wiring harness to external devices or systems. The cover opening is designed to offer ease of use, making it simpler to perform maintenance, replacements, or upgrades without needing to fully remove the cover. Depending on the design, the opening also allows for heat dissipation, air circulation, or routing for additional wires, ensuring optimal performance and safety. The slotted openings are employed for multiple wires or connectors to pass through a single gap, offering flexibility for wiring configurations. The method for creating a cover opening involves carefully designing the opening during the moulding or fabrication process. Depending on the application, the opening is reinforced with a rubber gasket or sealing material to ensure a proper fit and maintain the protective capabilities of the cover.
As used herein, the term “mounting slot” refers to a groove or aperture on the top of the protective cover, intended to allow for secure attachment or mounting of the cover to a fixed surface or another component. The mounting slot facilitates easy and stable installation of the load side cover within a larger system, ensuring that the wiring harness and its protective components remain securely in place during operation. The slot is essential for applications for the assembly to be mounted on a panel, chassis, or other mechanical structures, ensuring the wiring is properly organized and protected from environmental factors like vibrations or physical stress.
As used herein, the terms “fasteners” and “fastening means” are used interchangeably and refer to a fastening tool used to securely hold together various parts of the wiring harness, such as cables, connectors, and the assembly's protective coverings. The fasteners ensure that the wiring harness components are properly aligned, stable, and resistant to movement or vibration during operation. The fasteners are essential for maintaining the integrity of the wiring system, preventing any loose connections, and ensuring the safety and longevity of the power supply system. The types of fasteners commonly used in wiring harness assemblies include cable ties (zip ties), screws and bolts (used for attaching connectors or harnesses to mounts or enclosures), rivets (used for attaching components for a permanent fixture), and clips and clamps (used to secure the wires to specific mounting points or channels within the harness assembly). The fasteners are installed during the assembly process, ensuring the wires are held securely in place and that the harness is routed and organized to meet functional and safety requirements.
As used herein, the term “front cover” refers to an additional protective component that attaches to the front of the load side cover, providing an extra layer of shielding for the connectors and wiring at the load side of the harness. The front cover helps to protect the internal electrical components from environmental factors such as dust, moisture, chemicals, and physical damage. The front cover is designed to provide further insulation, safety, and protection, ensuring that the wiring remains intact and that no external factors interfere with the performance of the system. The front cover may also serve as a barrier to prevent accidental contact with live parts, enhancing safety during operation. Snap-on or clip-on front covers are commonly used for ease of installation and removal, allowing for quick access for maintenance or troubleshooting. The screw-on or bolt-on front covers are used in applications that require a more secure and permanent attachment, offering better protection against harsh environments or mechanical stress. Additionally, sealed or gasketed front covers are employed to provide water and dust protection, ensuring an airtight seal. Fastening mechanisms such as clips, screws, or snap fittings are then used to secure the front cover in place.
As used herein, the term “load side connecting module” refers to a component that facilitates the connection between the wiring harness and the electrical load. The module typically contains connectors, terminals, or other interfaces that allow for easy and secure electrical connections between the wiring harness and the load side components. The module is designed to ensure reliable power delivery, protect against accidental disconnections, and reduce the risk of short circuits or other electrical failures. The load side connecting module often includes features for strain relief, ensuring that the cables and connections remain intact under mechanical stress or vibration. Modular connector types are common, as individual pins or blocks are added or removed to configure the system based on the load requirements. Fixed connector modules are used for applications requiring a permanent and secure connection. The method of integrating a load side connecting module into the wiring harness involves designing the module to match the specific electrical and mechanical requirements of the load. The connectors or terminals within the module are aligned with the wiring harness, ensuring a secure fit.
As used herein, the term “connector holes” refers to the openings within the module that are used to house and secure the electrical connectors or terminals. The holes allow the individual wires or conductors from the wiring harness to connect to the load side of the assembly, facilitating the transfer of electrical power to the connected components or devices. The connector holes are critical for ensuring that each wire is properly aligned, connected, and securely held in place, preventing loose connections, which leads to electrical failures or power interruptions. Additionally, the design of the connector holes often includes features such as, locking mechanisms or alignment guides to ensure proper insertion and connection of the terminals. The types of connector holes in a load side connecting module are tailored for the requirements of the specific electrical components or systems being connected. The round or cylindrical connector holes are commonly used for standard wire terminals or pins, offering a secure fit for various wire gauges. Multi-pin connector holes are designed for applications that require connecting multiple conductors at once, typically found in larger assemblies or systems with multiple loads. The method of creating connector holes involves precise engineering during the moulding or machining process, where the holes are formed to specific dimensions and tolerances to fit the connectors properly. The design ensures that the connectors are securely housed within the holes and include features such as locking mechanisms or retention clips that hold the connectors in place, ensuring durability and a stable electrical connection throughout the life of the harness assembly.
As used herein, the term “securing slots” refers to the grooves or apertures incorporated into the module that serve to secure the wiring harness or connectors in place. The slots are critical for preventing movement or disconnection of the wires or terminals connected to the module. By providing a means to secure the connections, securing slots help ensure a stable, long-lasting, and reliable electrical connection between the wiring harness and the load side components, reducing the risk of mechanical stress, vibration, or accidental detachment. The types of securing slots depend on the specific requirements of the application. The basic slotted designs allow for the insertion of retention clips, cable ties, or locking pins to hold the wiring securely in place. The keyed securing slots ensure proper alignment and prevent incorrect installation by restricting the placement of connectors to specific positions. The method for creating secure slots involves incorporating the slots into the module during the moulding or manufacturing process. Consequently, as the module is assembled, connectors or wires are inserted into the securing slots, and appropriate locking mechanisms or retention clips are applied to ensure the components remain securely attached.
In accordance with an aspect of the present disclosure, there is provided a power supply wiring harness assembly for connecting a load and a power source, the assembly comprises:
- at least one high-voltage cable comprising a power source end and a load end;
- at least one source side connector; and
- at least one load side connector,
wherein the at least one load side connector is accommodated within a load side cover.
Referring to figure 1, in accordance with an embodiment, there is described a power supply wiring harness assembly for connecting a load and a power source. The assembly 100 comprises at least one high-voltage cable 102 comprising a power source end 104 and a load end 106, at least one source side connector 108 and at least one load side connector 110. Further, the at least one load side connector 110 is accommodated within a load side cover 112. Furthermore, the power source end 104 of the at least one high-voltage cable 102 is attached to the at least one source side connector 108 via at least one source side overmould 114 and wherein the load end 106 of the at least one high-voltage cable 102 is attached to the at least one load side connector 110 via a load side overmould 116. Furthermore, the load side overmould 116 comprises an upper end 118 and a lower end 120, and wherein the upper end 120 comprises a plurality of wire openings 122 and a plurality of locking slots 124. Furthermore, the load side overmould 116 is attached with the load side cover 112 via a rubber sleeve 126 and wherein the rubber sleeve 126 comprises a connector opening 128 and a plurality of fastening slots 130. Furthermore, the load side cover 112 comprises a front surface 132, a top surface 134, a left surface 136, a right surface 138 and a bottom surface 140, and wherein the top surface 134 comprises a cover opening 142, and a plurality of mounting slots 144. Furthermore, the load side overmould 116, the rubber sleeve 126 and the load side cover 112 are attached via a plurality of fastening means 146 passing through the plurality of wire openings 122, the plurality of fastening slots 130 and the plurality of mounting slots 144. Furthermore, the front surface 132 is configured to attach a front cover 148 via a load side connecting module 150. Furthermore, the load side connecting module 150 comprises a plurality of connector holes 152 and a plurality of securing slots 154.
The power supply wiring harness assembly 100 is designed to efficiently connect a load and a power source, enabling efficient transfer of high-voltage electrical power. The assembly 100 includes at least one high-voltage cable 102 that has a power source end 104 and a load end 106, which are designed to establish secure electrical connections with the source side connector 108 and load side connector 110. The connectors facilitate proper alignment and reliable electrical contact, ensuring the secure attachment of the cable to both ends. The load side connector 110 is specifically accommodated within a load side cover 112, providing additional protection and insulation for the electrical components, shielding the connector from environmental hazards such as moisture, dust, or physical damage. The load side cover 112 serves as a protective enclosure for the connector, ensuring that the connector remains securely housed and preventing exposure to external factors. The secure connections between the high-voltage cable and the source and load connectors ensure stable power transmission with minimal risk of electrical faults or disconnections. The accommodation of the load side connector 110 within the load side cover 112 enhances the overall protection by preventing contamination, reducing the likelihood of wear and tear, and ensuring insulation is maintained. The design minimizes the risk of electrical shorts, overheating, and other failures, particularly in high-voltage or rugged environments. The key advantages of this configuration include enhanced durability, improved safety, and a simplified assembly process. The assembly 100 is easier to install, maintain, and replace due to its modular design, and ensures the long-term reliability of the system.
In an embodiment, the power source end 104 of the at least one high-voltage cable 102 is attached to the at least one source side connector 108 via at least one source side overmould 114 and wherein the load end 106 of the at least one high-voltage cable 102 is attached to the at least one load side connector 110 via a load side overmould 116. The power wiring harness assembly 100 described involves high-voltage cables 102 with connectors 108, 110 at both ends, enabling efficient and secure electrical power transfer between components. Specifically, at the source end 104, the high-voltage cable is attached to the source side connector 108 through an overmould 114, which provides insulation and mechanical protection. Similarly, at the load end 106, the cable is connected to the load side connector 110 via a load side overmould 116. The overmoulding process involves encasing the connectors and cable joints with a layer of durable, insulating material, ensuring robust electrical isolation and protecting the connectors from environmental factors such as moisture, vibration, and physical stress. The assembly 100 ensures that the high-voltage cables are securely connected and insulated, minimizing the risk of electrical faults or hazards. Consequently, overmoulding ensures that high-voltage cables are securely fixed to the connectors and maintains proper insulation, reducing the risk of electrical short circuit, and improving the overall lifespan of the assembly. The advantages include enhanced safety, lower maintenance costs, and a more resilient wiring system.
In an embodiment, the load side overmould 116 comprises an upper end 118 and a lower end 120 and wherein the upper end 120 comprises a plurality of wire openings 122 and a plurality of locking slots 124. The load side overmould 116 is designed with both functional and structural features to ensure secure attachment and protection for the high-voltage cable in the power wiring harness assembly. The wire openings 122 are precisely sized to allow the high-voltage cables to pass through securely, ensuring a snug fit for each wire, and the locking slots engaging with corresponding features on the load side connector 110. The above-mentioned configuration ensures that the cable 102 remains securely in place, minimizing the risk of accidental disconnections or loosening during operation. Additionally, the locking slots 124 also provide an additional layer of stability by preventing the cable from slipping out of position or shifting under mechanical stress or vibration. The wire openings 122 and locking slots 124 work together to create a firm and secure connection between the cable 102 and the connector. The load side overmould’s 116 precise geometry and locking mechanism also prevent the cable from being subjected to excess movement or strain, reducing wear on the wires and connectors over time. The overall advantage is an improved connection that reduces the risk of failure and contributes to the longevity and safety of the system. Furthermore, the assembly 100 process is simplified as the locking system ensures proper alignment and retention, decreasing the chances of human error during installation, translating into fewer maintenance issues, reduced downtime, and higher operational efficiency in high-voltage applications.
In an embodiment, the at least one high-voltage cable 102 is attached to the at least one load side connector 110 via the plurality of wire openings 122. In the power wiring harness assembly, the high-voltage cable 102 is securely attached to the load side connector 110 through the plurality of wire openings 122 within the load side overmould 116. Specifically, each wire opening is designed to accommodate the individual conductors of the high-voltage cable, ensuring that the cable is inserted precisely and securely into the connector. The wire openings 122 align with the conductive pins or contacts in the load side connector 110, allowing for effective electrical continuity and a stable mechanical connection. Further, the openings 122 ensure that the cable conductors are correctly positioned and held firmly, reducing the risk of any loose connections that could lead to signal degradation or electrical faults. Furthermore, by utilizing wire openings 122 that align perfectly with the connector 110, the system ensures proper contact between the cable conductors and the connector’s terminals, ensuring a stable and low-resistance electrical path. The precise fit also minimizes the potential for mechanical strain or damage to the conductors over time, even in high-vibration environments. The advantages of the setup include improved electrical performance, enhanced safety by reducing loose or intermittent connections, and increased durability of the entire assembly. The design also simplifies the assembly process by ensuring proper alignment of components during installation, which reduces the risk of errors and improves the overall efficiency of manufacturing and maintenance operations.
In an embodiment, the load side overmould 116 is attached with the load side cover 112 via a rubber sleeve 126 and wherein the rubber sleeve 126 comprises a connector opening 128 and a plurality of fastening slots 130. The load side overmould 116 is securely attached to the load side cover 112 through a rubber sleeve 126, which acts as a mechanical and sealing interface between these components. Particularly, the rubber sleeve 126 features a connector opening 128 that is precisely sized to allow the load side connector 110 to pass through while maintaining a tight seal. Additionally, the rubber sleeve incorporates a plurality of fastening slots 130, which are designed to engage with corresponding features on the load side cover 112, creating a secure attachment that helps prevent any unwanted movement or separation between the overmould 116 and cover 112. The fastening slots 130 also allow for easy installation and secure fastening of the rubber sleeve 126, ensuring that the overmould 116 and cover 112 remain firmly connected during both assembly and operation. The rubber sleeve’s 126 connector ensures that the load side connector is positioned correctly and sealed properly, preventing contaminants such as moisture, dust, or chemicals from entering the connector and potentially causing damage. The fastening slots 130 further improve the stability of the connection, reducing the risk of mechanical strain or loosening under vibration or external forces. The advantages of the configuration include improved durability, better environmental protection, and increased safety of the wiring harness, particularly in high-voltage or harsh operational conditions. Furthermore, the design allows for easy assembly and maintenance, as the rubber sleeve facilitates a quick, secure connection offering flexibility for disassembly.
In an embodiment, the load side cover 112 comprises a front surface 132, a top surface 134, a left surface 136, a right surface 138 and a bottom surface 140, and wherein the top surface 134 comprises a cover opening 142, and a plurality of mounting slots 144.
In an embodiment, the load side overmould 116, the rubber sleeve 126 and the load side cover 112 are attached via a plurality of fastening means 146 passing through the plurality of wire openings 122, the plurality of fastening slots 130 and the plurality of mounting slots 144. The load side overmould 116, the rubber sleeve 126, and the load side cover 112 are securely assembled using a plurality of fastening means 146 that pass through the wire openings 122, the fastening slots 130, and the mounting slots 144. The multi-component assembly ensures that all parts are firmly connected, creating a unified structure that holds the high-voltage cable and connector in place. The fastening means 146 are designed to pass through the wire openings, aligning the components in a precise configuration, which ensures proper alignment of the cable conductors with the connector. Additionally, the fastening slots 130 and mounting slots 144 contribute to a stable mechanical connection between the rubber sleeve 126 and the load side cover 112, effectively securing the components against external stresses such as vibration, thermal expansion, or mechanical impact. The use of fastening means 146 to secure the load side overmould 116, rubber sleeve 126, and cover 112 ensures that the components remain aligned and tightly connected, preventing movement or loosening over time. The above-mentioned configuration results in a stable electrical and mechanical connection, reducing faults or failures due to poor contact or loose connections. The advantages of the approach include increased reliability, durability, and safety. Moreover, the fastener-based assembly provides a straightforward method for installation and maintenance, allowing for efficient assembly and enabling easy disassembly for repairs or upgrades.
In an embodiment, the front surface 132 is configured to attach a front cover 148 via a load side connecting module 150. The front surface 132 of the load side overmould 116 is specifically designed to facilitate the attachment of a front cover 148 via a load side connecting module 150. The above-mentioned configuration enables the front cover 148 to be securely fastened over the connector area, providing both mechanical protection and environmental shielding for the high voltage wiring and connectors. The load side connecting module 150 ensures that the front cover 148 is aligned and attached correctly to the front surface 132, locking the components in place and preventing any unintended movement or exposure to external elements. The module 150 is designed to securely hold the cover, ensuring that the wiring and connectors are protected from contaminants like dust, moisture, or chemicals. By using a front cover 148 attached via the load side connecting module 150, the system benefits from additional environmental sealing, safeguarding the internal components against damage from external forces. The setup also improves safety by minimizing the risk of accidental contact with live components, particularly the high-voltage cables. The advantages of the configuration include increased durability, as the front cover 132 helps prevent wear and tear on exposed components, and improved operational longevity, as the protective cover reduces the risk of environmental damage. Moreover, the modular attachment approach simplifies the assembly and maintenance processes, enabling quick installation and removal of the front cover for inspection or servicing.
In an embodiment, the load side connecting module 150 comprises a plurality of connector holes 152 and a plurality of securing slots 154. The load side connecting module 150 is designed to enhance the mechanical and electrical connectivity of the power wiring harness by incorporating a plurality of connector holes 152 and securing slots 154. The connector holes 152 are precisely aligned to receive the connectors or pins from the load side connector 110, ensuring a stable and secure electrical connection between the cables and the rest of the system. The holes 152 are designed to accommodate specific connector types, ensuring that the correct alignment and contact are achieved for optimal electrical performance. The securing slots 154 work in conjunction with the connector holes by providing a mechanical attachment point, locking the connectors and their corresponding components into place. The securing slots 154 ensure that the connectors are held securely within the connecting module 150, preventing accidental disconnection or loosening during operation. Further, the precise alignment of the connector holes 152 ensures that each conductor or terminal is securely seated within the module, maintaining a reliable and low-resistance electrical connection. The use of securing slots 154 enhances the robustness of the assembly by reducing the risk of connector movement or loosening, which is critical in high-vibration or high-temperature environments. The advantages of the design include increased reliability, durability, and safety of the overall system. By preventing inadvertent disconnections and ensuring stable electrical pathways, this setup reduces the risk of system failure, improving operational efficiency and longevity. Additionally, the modular design simplifies the assembly process and makes maintenance easier, as components are easily accessed, replaced, or serviced without disassembling the entire system.
In an embodiment, the front surface 132 is attached to the front cover 148 via a plurality of fasteners 156 passing through the plurality of securing slots 154. The front surface 132 of the load side overmould 116 is attached to the front cover 148 through a plurality of securing slots 154, which provides a secure and stable method for fastening the two components together. The securing slots 154 are designed to align with corresponding features on the front cover 148, allowing for a firm connection. The securing slots 154 on the front surface 132 are engaged with the corresponding securing features on the front cover 148, the two parts are locked into position, creating a seamless and protective enclosure for the electrical components within the harness. The design ensures that the front cover 148 remains securely in place, protecting the high-voltage connections from external contaminants, mechanical stress, and environmental factors such as moisture or dust. By ensuring that the front cover 148 is securely attached to the front surface 132, the system experiences less loosening or dislodging of the cover under operational conditions, such as vibration or thermal expansion. The advantages of the design include improved durability, protection of critical internal components, and enhanced safety by preventing exposure to potentially hazardous electrical connections. Additionally, the securing slot-based method simplifies assembly, making the assembly easier to install and remove the front cover for maintenance.
Based on the above-mentioned embodiments, the present disclosure provides significant advantages such as (but not limited to) improved organization, reduced risk of electrical faults, and enhanced durability by securely routing and protecting wires, and a more reliable, long-lasting power transmission, minimizing maintenance needs and increasing the overall safety and efficiency of the assembly.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combinations of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, and “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A power supply wiring harness assembly (100) for connecting a load and a power source, the assembly (100) comprises:
- at least one high-voltage cable (102) comprising a power source end (104) and a load end (106);
- at least one source side connector (108); and
- at least one load side connector (110),
wherein the at least one load side connector (110) is accommodated within a load side cover (112).

2. The assembly (100) as claimed in claim 1, wherein the power source end (104) of the at least one high-voltage cable (102) is attached to the at least one source side connector (108) via at least one source side overmould (114) and wherein the load end (106) of the at least one high-voltage cable (102) is attached to the at least one load side connector (110) via a load side overmould (116).

3. The assembly (100) as claimed in claim 2, wherein the load side overmould (116) comprises an upper end (118) and a lower end (120) and wherein the upper end (118) comprises a plurality of wire openings (122) and a plurality of locking slots (124).

4. The assembly (100) as claimed in claim 1, wherein the at least one high-voltage cable (102) is attached to the at least one load side connector (110) via the plurality of wire openings (122).

5. The assembly (100) as claimed in claim 1, wherein the load side overmould (116) is attached with the load side cover (112) via a rubber sleeve (126) and wherein the rubber sleeve (126) comprises a connector opening (128) and a plurality of fastening slots (130).

6. The assembly (100) as claimed in claim 1, wherein the load side cover (112) comprises a front surface (132), a top surface (134), a left surface (136), a right surface (138) and a bottom surface (140) and wherein the top surface (134) comprises a cover opening (142), and a plurality of mounting slots (144).

7. The assembly (100) as claimed in claim 2, wherein the load side overmould (116), the rubber sleeve (126) and the load side cover (112) are attached via a plurality of fastening means (146) passing through the plurality of wire openings (122), the plurality of fastening slots (130) and the plurality of mounting slots (144).

8. The assembly (100) as claimed in claim 6, wherein the front surface (132) is configured to attach a front cover (148) via a load side connecting module (150).

9. The assembly (100) as claimed in claim 8, wherein the load side connecting module (150) comprises a plurality of connector holes (152) and a plurality of securing slots (154).

10. The assembly (100) as claimed in claim 6, wherein the front surface (132) is attached to the front cover (148) via a plurality of fasteners (156) passing through the plurality of securing slots (154).