Description:A wire harness routing structure for an electric vehicle
Field of the Invention
The present invention relates to a wire harnessing for an electric vehicle. More particularly, the present invention relates to wire harness routing structure for connection with battery and remaining battery driven parts of the electric vehicle.
Background of the Invention
Wiring harnesses play a critical role in the functioning of electric vehicles, serving as the system that connects various components, including batteries, motors, sensors, and controllers. However, they also pose significant challenges, particularly in three-wheeler electric vehicles, electric cars, and high-end electric vehicles where intricate wiring configurations are necessary to accommodate complex electrical systems.
One common technical problem in wiring harnesses is improper routing, especially concerning the proximity to batteries and other crucial components. Inadequate routing can lead to issues such as chafing, abrasion, or exposure to heat, potentially resulting in short circuits, electrical arcing, or even fire hazards. Ensuring proper insulation and securing the harness away from high-temperature areas or sharp edges is essential to mitigate these risks.
Moreover, the integration of advanced features in high-end electric vehicles introduces additional complexities to wiring harnesses. These vehicles often incorporate sophisticated electronic systems for functions like autonomous driving, regenerative braking, and connectivity. Managing the increased number of wires and connectors while maintaining reliability and performance becomes a significant challenge. Any malfunction or disruption in the wiring harness can compromise the functionality of these advanced features, affecting vehicle safety and performance.
In three-wheeler electric vehicles, where space is limited, designing an efficient and compact wiring harness becomes crucial. The layout must account for the unique structure of these vehicles while ensuring optimal performance and durability. Additionally, the vibration and harsh operating conditions experienced by three-wheeler electric vehicles demand robust wiring harness designs capable of withstanding constant movement and environmental stressors.
Continuous innovation in materials, routing techniques, and manufacturing processes is essential to overcome the complexities associated with wiring harnesses in electric vehicles, ensuring they meet the stringent safety and quality standards in a compact structure as demanded by the automotive industry.
In the existing prior arts, the wire connection between battery source and power supply points consumes wire length in high magnitude or twisted because of which there arises an issue of power cut resulting in malfunctioning of the components.
It is, therefore, desirable to develop an improved wire harness routing structure for electric vehicles that overcomes challenges and obviates complexity existing in the prior arts.
Summary of the Invention
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this summary intended to be used to limit the claimed subject matter’s scope.
Both the foregoing summary and the following detailed description provide examples and are explanatory only. Accordingly, the foregoing summary and the following detailed description should not be considered to be restrictive. Further, features or variations may be provided in addition to those set forth herein. For example, embodiments may be directed to various feature combinations and sub-combinations described in the detailed description.
It is one of the objectives of the present invention to provide a wire harness routing structure for connecting battery units with power supply points of an electric vehicle.
It is one of the objectives of the present invention to provide a wire harness routing structure for connecting battery units with power supply points by using minimum wire length.
It is one of the objectives of the present invention to provide a wire harness routing structure for connecting battery units with power supply points in one-sided arrangement in an electric vehicle.
It is one of the objectives of the present invention to provide a wire harness routing structure which is integrated with the battery mounting assembly for three-wheeler, cars, trucks or buses.
It is one of the objectives of the present invention to provide a wire harness routing structure which avoids alteration in the existing design of the vehicle.
It is one of the objectives of the present invention to provide a wire harness routing structure which is maintenance friendly.
It is one of the objectives of the present invention to provide a wire harness routing structure which helps to collect maximum power or required maximum power in shortest wire distance for power supply from batteries.
As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.
Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure and are made merely for the purposes of providing a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.
Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein—as understood by the ordinary artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail.
Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. When used herein to join a list of items, “or” , “/” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.”
In accordance with one embodiments of the present invention, there is provided a wire harness routing structure for electric vehicle, wherein wire harness routing structure comprises of a plurality of wire insertion hooks provided on rear side of a plurality of battery units housed adjacent to each other within a battery mounting assembly, and a wire harness comprising a main wire extending substantially through the plurality of wire insertion hooks along rear length and width of the battery assembly for connecting an electronic control unit (ECU) with said plurality of battery units, a battery junction box integrated with the battery mounting assembly on its rear side and various equipment of the vehicle.
In accordance with one embodiments of the present invention, there is provided a wire harness routing structure for electric vehicle, wherein wire harness routing structure comprises of a plurality of wire insertion hooks provided on rear side of a plurality of battery units housed adjacent to each other within a battery mounting assembly, and a wire harness comprising a main wire extending substantially through the plurality of wire insertion hooks along rear length and width of the battery assembly for connecting an electronic control unit (ECU) directly mounted on to the top of a battery mounting assembly with said plurality of battery units, a battery junction box integrated with the battery mounting assembly on its rear side and various equipment of the vehicle, wherein said wire harness further comprises of one or more wires originating from output of each said battery unit and connecting to the main wire.
In accordance with one embodiments of the present invention, there is provided a wire harness routing structure for electric vehicle, wherein wire harness routing structure comprises of a plurality of wire insertion hooks provided on rear side of a plurality of battery units housed adjacent to each other within a battery mounting assembly, and a wire harness comprising a main wire extending substantially through the plurality of wire insertion hooks along rear length and width of the battery assembly for connecting an electronic control unit (ECU) directly mounted on to the top of a battery mounting assembly with said plurality of battery units, a battery junction box integrated with the battery mounting assembly on its rear side and various equipment of the vehicle, wherein said wire harness comprising one or more sub-main wires for connecting the battery junction box and output of each said battery unit.
In accordance with one embodiments of the present invention, there is provided a wire harness routing structure for electric vehicle, wherein wire harness routing structure comprises of a plurality of wire insertion hooks provided on rear side of a plurality of battery units housed adjacent to each other within a battery mounting assembly, and a wire harness comprising a main wire extending substantially through the plurality of wire insertion hooks along rear length and width of the battery assembly for connecting an electronic control unit (ECU) directly mounted on to the top of a battery mounting assembly with said plurality of battery units, a battery junction box integrated with the battery mounting assembly on its rear side and various equipment of the vehicle, wherein said battery mounting assembly is mounted on to rear downside along width and on to a chassis of the electric vehicle.
In accordance with one embodiments of the present invention, there is provided a wire harness routing structure for electric vehicle, wherein wire harness routing structure comprises of a plurality of wire insertion hooks provided on rear side of a plurality of battery units housed adjacent to each other within a battery mounting assembly, and a wire harness comprising a main wire extending substantially through the plurality of wire insertion hooks along rear length and width of the battery assembly for connecting an electronic control unit (ECU) directly mounted on to the top of a battery mounting assembly with said plurality of battery units, a battery junction box integrated with the battery mounting assembly on its rear side and various equipment of the vehicle, wherein said battery mounting assembly is having cradle-based structure designed to comprise plurality of casings for housing and enabling swapping of the plurality of batteries along the width of the vehicle.
In accordance with one embodiments of the present invention, there is provided a wire harness routing structure for electric vehicle, wherein wire harness routing structure comprises of a plurality of wire insertion hooks provided on rear side of a plurality of battery units housed adjacent to each other within a battery mounting assembly, and a wire harness comprising a main wire extending substantially through the plurality of wire insertion hooks along rear length and width of the battery assembly for connecting an electronic control unit (ECU) directly mounted on to the top of a battery mounting assembly with said plurality of battery units, a battery junction box integrated with the battery mounting assembly on its rear side and various equipment of the vehicle, wherein said electric vehicle is a three-wheeler or four-wheeler or a truck or a bus.
Brief Description of the accompanying drawing
Figure 1 shows perspective view of the wire harness routing structure for battery units housed in battery mounting assembly.
Detailed Description of the Invention
The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims. The present disclosure contains headers. It should be understood that these headers are used as references and are not to be construed as limiting upon the subjected matter disclosed under the header.

Referring to Figure 1, there is provided a wire harness routing structure in a cradle type structure (7) within which battery casings (3) are accommodated for allowing battery swapping as and when required. The cradle type structure surrounds the battery casings (3) and mounts electronic control unit (ECU) (2) on its top surface (4) at one of the ends of the cradle type structure along its width. A main wire (5) extends from the ECU (2) to pass through one or more wire insertion hooks (13) provided in each of the battery unit (14). A junction box (10) mounted on the back portion of the cradle type structure (7) is connected to the output (15) of the battery units (14) by way of sub-main wire harness (16) along the width of the cradle type structure (7) and passing through wire insertion hooks (17) from one side to another. Further, the output (15) of each of the battery units is also connected through short wires (13) to the main wire (5) starting from the output of the ECU (2) and extending from one side to another side along width of the cradle type structure (7) for supplying and distributing electrical power and coordinating with various components of the vehicle. The cradle type structure (7) is preferably mounted on the rear portion (6) of the three-wheeler vehicle. The cradle type structure (7) is also referred to as “battery mounting assembly”. The cradle type structure is supported by vibration isolating dampers (12).
Also, to prove ease of serviceability in terms of accessing ECU connections from rear side of the vehicle, the arrangement of ECU (2) on to the battery mounting assembly (7) also helps to protect ECU (2) from direct exposure to dust and water as it is being placed at higher position and covered and packaged under vehicle body. Further, as the cradle structure (7) is supported on vibration isolation dampers (12), it protects ECU (2) and attached power supply system from unwanted high vibrations and extends its life. The main wire (5), short wires (13) and sub-main wire (16) of the wiring harness along the hooks (17) and connection on the same plane of the back side of the cradle type structure, enables easy maintenance and servicing.
While the invention is amenable to various modifications and alternative forms, some embodiments have been illustrated by way of example in the drawings and are described in detail above. The intention, however, is not to limit the invention by those examples and the invention is intended to cover all modifications, equivalents, and alternatives to the embodiments described in this specification.

The embodiments in the specification are described in a progressive manner and focus of description in each embodiment is the difference from other embodiments. For same or similar parts of each embodiment, reference may be made to each other.

It will be appreciated by those skilled in the art that the above description was in respect of preferred embodiments and that various alterations and modifications are possible within the broad scope of the appended claims without departing from the spirit of the invention with the necessary modifications.

Based on the description of disclosed embodiments, persons skilled in the art can implement or apply the present disclosure. Various modifications of the embodiments are apparent to persons skilled in the art, and general principles defined in the specification can be implemented in other embodiments without departing from the spirit or scope of the present disclosure. Therefore, the present disclosure is not limited to the embodiments in the specification but intends to cover the most extensive scope consistent with the principle and the novel features disclosed in the specification. , Claims:We Claim:

1. A wire harness routing structure for electric vehicle, comprises of:
a plurality of wire insertion hooks (17) provided on rear side of a plurality of battery units (14) housed adjacent to each other within a battery mounting assembly (7); and
a wire harness (1) comprising a main wire (5) extending substantially through the plurality of wire insertion hooks (17) along rear length and width of the battery assembly (7) for connecting an electronic control unit (ECU) (2) directly mounted on to the top of a battery mounting assembly (7) with said plurality of battery units (14), a battery junction box (10) integrated with the battery mounting assembly (7) on its rear side and various equipment of the vehicle.
2. The wire harness routing structure as claimed in claim 1, wherein said wire harness (1) further comprises of one or more wires (13) originating from output (15) of each said battery unit (14) and connecting to the main wire (5).
3. The wire harness routing structure as claimed in claim 1, wherein said wire harness (1) comprising one or more sub-main wires (16) for connecting the battery junction box (10) and output (15) of each said battery unit (14).
4. The wire harness routing structure as claimed in claim 1, wherein said battery mounting assembly (7) is mounted on to rear downside (6) along width and on to a chassis of the electric vehicle.
5. The wire harness routing structure as claimed in claim 1, wherein said battery mounting assembly (7) is having cradle-based structure designed to comprise plurality of casings (3) for housing and enabling swapping of the plurality of batteries along the width of the vehicle.
6. The wire harness routing structure as claimed in claim 1, wherein said electric vehicle is a three-wheeler or four-wheeler or a truck or a bus.