Description:FIELD OF INVENTION
[0001] The present invention is generally related to a wiring system for a vehicle, and more particularly to a modular harness system for use with a vehicle.
BACKGROUND OF INVENTION
[0002] An electric two-wheeler relies on a wiring harness, its central nervous system, to keep everything functioning smoothly. This network of insulated wires acts as a highway, carrying electrical power from the battery to power the motor controller, lights, and instruments. It also transmits control signals between these components, allowing them to communicate and work together seamlessly. The wiring harness does not just deliver power, it also protects the electrical system from short circuits and current leaks, ensuring a safe and reliable ride. Finally, by bundling all the wires together, the harness keeps things organized, making assembly, maintenance, and troubleshooting a breeze.
[0003] Electric two-wheeler manufacturers face hurdles with current wiring harnesses. Firstly, managing a variety of harnesses for different vehicle models creates a large inventory burden for factories and service centers. Secondly, using a single harness for all models becomes impractical as higher battery and motor power demands require thicker wires, leading to bulkiness, routing difficulties, and unnecessary full harness replacements for minor faults. Finally, the increasing number of electronic devices and higher speed demands contribute to heavier and bulkier harnesses, making them cumbersome for assembly workers to route.
[0004] In recognition of the challenges posed by existing wiring harnesses of the various vehicle models, the difficulty of servicing single bulky harnesses, and the weight and routing issues they cause, this specification proposes a modular harness system. The modular harness system addresses these shortcomings by offering a more flexible and adaptable solution.
[0005] Thus, in view of the above, there is a long-felt need in the industry to address the aforementioned deficiencies and inadequacies.

SUMMARY OF THE INVENTION
[0006] A vehicle modular harness system is provided substantially, as shown in and/or described in connection with at least one of the figures.
[0007] An aspect of the present disclosure relates to a modular harness system for use with a vehicle. The modular harness system includes a wiring harness, a battery cable, and a Master Vehicle Control Unit (MVCU) pigtail connector. The wiring harness is configured to distribute electrical signals and power to a plurality of electrical components within the vehicle. The battery cable is configured to establish an electrical connection between a battery of the vehicle and the electrical components and supplies power to the electrical components to perform a vehicle operation. The Master Vehicle Control Unit (MVCU) pigtail connector is configured to detachably connect the wiring harness and the battery cable.
[0008] In an aspect, the MVCU pigtail connector includes a plurality of pins for transmitting power, ground, and signal lines between the wiring harness and the battery cable.
[0009] In an aspect, the battery cable includes a battery cable ring terminal, a battery cable Amphenol connector, and a battery cable chogori connector.
[0010] In an aspect, the battery cable is constructed with a high-gauge wire to handle the high current loads required for the vehicle operation.
[0011] In an aspect, the MVCU pigtail connector is configured with a locking mechanism to secure the connection between the wiring harness and the battery cable.
[0012] In an aspect, the wiring harness and the battery cable are shielded to reduce electromagnetic interference (EMI) within an electrical system of the vehicle.
[0013] In an aspect, the wiring harness is designed in a modular way to allow for easy replacement and upgrading of individual sections of a main harness.
[0014] In an aspect, the MVCU pigtail connector is configured to connect the wiring harness to a Master Vehicle Control Unit (MVCU).
[0015] In an aspect, the MVCU includes a microcontroller configured to process input signals from a plurality of sensors and control outputs to one or more actuators within the vehicle.
[0016] Another aspect of the present invention is to provide a method for assembling a modular harness system for a vehicle. The method includes a step of connecting a wiring harness to a plurality of electrical components within the vehicle. The method includes a step of connecting a battery cable to a battery of the vehicle. The method includes a step of connecting, by using a Master Vehicle Control Unit (MVCU) pigtail connector, the wiring harness, and the battery cable.
[0017] Accordingly, one advantage of the present invention is that it divides the main harness into multiple parts and provides interconnections between them, facilitating the management of multiple projects by standardizing the main harness and adjusting the battery cable or MVCU pigtail connector according to the vehicle stock keeping unit (SKU). This modular harness system minimizes inventory at the plant, thereby reducing inventory costs. For multiple projects, a single wiring harness combined with either a different battery cable or an MVCU pigtail connector lowers inventory costs. Additionally, sudden changes in the manufacturing process can be easily accommodated using this modular harness concept.
[0018] One advantage of the present invention is that it simplifies the routing of the harness within the vehicle.
[0019] Another advantage of the present invention is that it allows operators to easily work in the manufacturing plant or service center.
[0020] These features and advantages of the present disclosure may be appreciated by reviewing the following description of the present disclosure, along with the accompanying figures wherein reference numerals refer to like parts.

BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings illustrate the embodiment of devices, systems, methods, and other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent an example of the boundaries. In some examples, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another and vice versa. Furthermore, the elements may not be drawn to scale.
[0022] Various embodiments will hereinafter be described in accordance with the appended drawings, which are provided to illustrate, not limit, the scope, wherein similar designations denote similar elements, and in which:
[0023] FIG. 1 illustrates an assembled view of a modular harness system for use with a vehicle, in accordance with at least one embodiment.
[0024] FIG. 2 illustrates a perspective view of a wiring harness, in accordance with at least one embodiment.
[0025] FIG. 3 illustrates a perspective view of a battery cable ring terminal, in accordance with at least one embodiment.
[0026] FIG. 4 illustrates a perspective view of a battery cable Amphenol connector, in accordance with at least one embodiment.
[0027] FIG. 5 illustrates a perspective view of a 20-pin MVCU pigtail, in accordance with at least one embodiment.
[0028] FIG. 6 illustrates a perspective view of a 16-pin MVCU pigtail, in accordance with at least one embodiment.
[0029] FIG. 7 illustrates a block diagram of the modular harness system, in accordance with at least one embodiment.
[0030] FIG. 8 illustrates an assembled view of the modular harness system in conjunction with an MVCU, in accordance with at least one embodiment.

DETAILED DESCRIPTION OF THE EMBODIMENTS HEREIN
[0031] The present disclosure is best understood with reference to the detailed figures and description set forth herein. Various embodiments have been discussed with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions provided herein with respect to the figures are merely for explanatory purposes, as the methods and systems may extend beyond the described embodiments. For instance, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond certain implementation choices in the following embodiments.
[0032] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.
[0033] Typically, a vehicle includes a main wiring harness that performs several crucial functions, including power distribution, signal transmission, interconnection, and protection. The main wiring harness distributes electrical power from the battery and alternator to various electrical components throughout the vehicle, such as lights, the ignition system, fuel injectors, and electronic control units (ECUs). Moreover, the main wiring harness carries electrical signals between different parts of the vehicle. These signals control various functions and operations, including engine management, transmission control, safety systems (such as airbags and ABS), and infotainment systems.
[0034] Additionally, the main wiring harness connects various sensors, switches, and actuators to the vehicle's control units, enabling the vehicle's systems to monitor and respond to changing conditions effectively. It also organizes and protects the wires from physical damage, environmental factors (such as heat and moisture), and electromagnetic interference, ensuring the reliable operation of the vehicle's electrical systems.
[0035] The present disclosure provides a system and method that divide the main wiring harness of the vehicle into distinct components: a wiring harness, a battery cable, and a Master Vehicle Control Unit (MVCU) pigtail connector. This modular approach allows for more efficient assembly, easier maintenance, and enhanced reliability by clearly separating the functions of power distribution, signal transmission, and interconnection within the vehicle's electrical system.
[0036] FIG. 1 illustrates an assembled view of a modular harness system 100 for use with a vehicle, in accordance with at least one embodiment. Examples of the vehicle include but are not limited to a two-wheeler electric vehicle and two-wheeler vehicle. The modular harness system 100 includes a wiring harness 102, a battery cable 104, and a Master Vehicle Control Unit (MVCU) pigtail connector 106. The wiring harness 102 is configured to distribute electrical signals and power to a plurality of electrical components within the vehicle. In an embodiment, the wiring harness 102 is designed in a modular way to allow for easy replacement and upgrading of individual sections of a main harness. The modular design simplifies maintenance and upgrades, reducing downtime and improving the overall lifespan of the vehicle's electrical system. The wiring harness 102 may include multiple connectors for interfacing with various vehicle systems such as lighting, infotainment, and safety systems. These connectors enable the wiring harness 102 to efficiently distribute electrical signals and power to various vehicle systems, ensuring their proper operation.
[0037] The battery cable 104 is configured to establish an electrical connection between a battery of the vehicle and the electrical components and supplies power to the electrical components to perform a vehicle operation. In an embodiment, the battery cable 104 is constructed with a high-gauge wire to handle the high current loads required for the vehicle operation. The high-gauge wire ensures reliable power delivery, minimizing voltage drop and ensuring sufficient current reaches the vehicle components. In an embodiment, the battery cable 104 includes a battery cable ring terminal 104a (shown in FIG. 3), a battery cable Amphenol connector 104b (shown in FIG. 4), and a battery cable Chogori connector (not shown). In an embodiment, the wiring harness 102 and the battery cable 104 are shielded to reduce electromagnetic interference (EMI) within an electrical system of the vehicle. The shielding protects against EMI, ensuring the integrity and reliability of electrical signals transmitted through the harness system.
[0038] The Master Vehicle Control Unit (MVCU) pigtail connector 106 is configured to detachably connect the wiring harness 102 and the battery cable 104. In an embodiment, the MVCU pigtail connector 106 is configured with a locking mechanism to secure the connection between the wiring harness 102 and the battery cable 104. The locking mechanism ensures a stable and secure connection, preventing accidental disconnection and ensuring consistent electrical performance.
[0039] FIG. 2 illustrates a perspective view of a wiring harness 102, in accordance with at least one embodiment. The wiring harness 102 serves as the primary electrical conduit within the vehicle, facilitating the distribution of electrical signals and power to various components and systems within the vehicle.
[0040] FIG. 3 illustrates a perspective view of a battery cable ring terminal 104a, in accordance with at least one embodiment. FIG. 3 is explained in conjunction with FIG. 1. The battery cable ring terminal 104a is configured to establish a secure electrical connection between the battery cable 104 and the vehicle's battery terminal. The battery cable ring terminal 104a ensures a reliable and stable connection to the battery, minimizing resistance and maintaining efficient power transfer.
[0041] FIG. 4 illustrates a perspective view of a battery cable Amphenol connector (104b), in accordance with at least one embodiment. FIG. 4 is explained in conjunction with FIG. 1. The battery cable Amphenol connector 104b is configured to provide a robust and quick-connect/disconnect interface between the battery cable 104 and the wiring harness 102. The battery cable Amphenol connector 104b facilitates easy and secure connections, allowing for quick assembly and maintenance of the electrical system.
[0042] The battery cable Chogori connector is configured to interface with specific electrical components within the vehicle, ensuring proper connectivity and signal transmission. The battery cable Chogori connector provides a tailored connection to specific vehicle components, ensuring compatibility and reliable performance within the electrical system.
[0043] The MVCU pigtail connector 106 includes a plurality of pins for transmitting power, ground, and signal lines between the wiring harness 102 and the battery cable 104. FIG. 5 illustrates a perspective view of a 20-pin MVCU pigtail, in accordance with at least one embodiment. FIG. 6 illustrates a perspective view of a 16-pin MVCU pigtail, in accordance with at least one embodiment. According to an embodiment herein, the MVCU pigtail connector 106 is water-resistant, ensuring reliable operation in various environmental conditions. The water-resistant design protects the electrical connections from moisture and contaminants, ensuring consistent performance in different weather conditions. The multiple pins facilitate comprehensive electrical interfacing, allowing for the transmission of power and data necessary for the vehicle's operations.
[0044] FIG. 7 illustrates a block diagram of the modular harness system, in accordance with at least one embodiment. FIG. 7 is explained in conjunction with FIG. 1. In operation, the MVCU pigtail connector 106 acts as a bridging interface, enabling the connection between the wiring harness 102 and the battery cable 104. The MVCU pigtail connector 106 includes an interconnection connector 106a, configured to connect the wiring harness 102 and the battery cable 104 using a Controller Area Network (CAN) connection. Furthermore, the MVCU pigtail connector 106 includes an interconnection connector 106b to provide a DCDC (“DC-DC” or “Direct Current to Direct Current”) supply from the wiring harness 102 to the battery cable 104. The DC-DC supply ensures the proper voltage levels are supplied to various electrical systems in the vehicle, supporting efficient power management, safety, and functionality.
[0045] The connection through the MVCU pigtail connector 106 ensures a streamlined and secure linkage between the main wiring harness and the battery cable, facilitating efficient electrical communication and power distribution. The MVCU pigtail connector's 106 interconnection capability allows for the modular assembly of the wiring harness 102 and the battery cable 104, promoting ease of installation, maintenance, and potential upgrades within the vehicle's electrical system.
[0046] FIG. 8 illustrates an assembled view of the modular harness system in conjunction with an MVCU, in accordance with at least one embodiment. FIG. 8 is explained in conjunction with FIG. 1. The MVCU pigtail connector 106 is configured to connect the wiring harness 102 to a Master Vehicle Control Unit (MVCU) 110. In an embodiment, the MVCU 110 includes a microcontroller configured to process input signals from a plurality of sensors and control outputs to one or more actuators within the vehicle. The microcontroller coordinates the operation of vehicle systems, enhancing performance, safety, and efficiency. Using the MVCU pigtail connector 106, a buyer can enhance the display experience by changing the OEM-approved MVCU (display) 110 even though having a different connector. The MVCU 110 is configured to monitor the status of the electrical components and provide diagnostic information to a user interface. The MVCU's monitoring capability enhances vehicle maintenance by providing real-time diagnostic information, aiding in the early detection of potential issues.
[0047] As used herein, and unless the context dictates otherwise, the term “configured to” or “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “configured to”, “configured with”, “coupled to” and “coupled with” are used synonymously. Within the context of this document terms “configured to”, “coupled to” and “coupled with” are also used euphemistically to mean “communicatively coupled with” over a network, where two or more devices can exchange data with each other over the network, possibly via one or more intermediary device.
[0048] Thus, the modular harness system (100) addresses the issues of inventory, serviceability, and the bulkiness of the wiring harnesses used in vehicles.
[0049] In two-wheeler electric vehicles, manufacturers (OEMs) typically use a single harness for each dedicated SKU vehicle model. This single harness contains all parts in one unit, leading to high costs, weight, and volume (space required to store the harness). When multiple SKU vehicles are involved, maintaining all types of harnesses in inventory increases costs and storage space requirements in the manufacturing plant. By dividing the single harness into two or three parts, such as a wiring harness, a battery cable, and an MVCU pigtail, manufacturers can keep a large quantity of the main harness and comparatively smaller quantities of battery cables. This modular approach allows for the manufacture of different SKU models. These models vary in terms of battery capacity (Ah), battery types, and types of instrument cluster displays (ICL) with different connectors, offering customers a variety of options for range and display features. Using different combinations, multiple SKU vehicles can be maintained by keeping different battery cables and MVCU pigtails in stock. This method also applies to service centers, allowing them to maintain a single harness for all SKU models while stocking different battery cables and MVCU pigtails for different ICLs. This approach reduces the inventory costs for both the manufacturing plant and the service center.
[0050] Additionally, dividing the main harness into three parts simplifies servicing. If an issue occurs with the harness, only the faulty part needs to be replaced, leaving the remaining parts intact in the vehicle. This reduces the time and effort required by the service team to replace just one section of the harness, such as the wiring harness, battery cable, or MVCU pigtail connector. This approach indirectly reduces service costs for the manufacturer, especially during the warranty period, and increases the efficiency of the service center. It also improves the efficiency of the manufacturing plant's rework area.
[0051] Furthermore, dividing the main harness into multiple parts reduces the harness's overall weight. Typically, the battery cable has a higher wire gauge, making it difficult to bend. By separating the battery cable, it becomes more easily bendable, reducing the bulkiness of the harness. This reduces operator fatigue, resulting in increased efficiency.
[0052] In one embodiment, the present invention provides a method for assembling a modular harness system for a vehicle. The method includes a step of connecting a wiring harness to a plurality of electrical components within the vehicle. The wiring harness is secured to various vehicle systems such as lighting, infotainment, and safety systems to ensure proper electrical distribution. The method includes a step of connecting a battery cable to a battery of the vehicle. This step establishes a connection between the battery cable and the vehicle's battery to facilitate power supply to the electrical components. The method includes a step of connecting, by using a Master Vehicle Control Unit (MVCU) pigtail connector, the wiring harness, and the battery cable. In this step, the MVCU pigtail connector is attached between the wiring harness and the battery cable to ensure a secure and efficient electrical connection.
[0053] In another embodiment, the present invention provides a method for operating a modular harness system in a vehicle. The method includes a step of distributing electrical signals and power from the wiring harness to a plurality of electrical components within the vehicle. The wiring harness is utilized to deliver electrical signals and power to various vehicle systems, ensuring their functionality. The method includes a step of supplying power from the battery through the battery cable to the electrical components to perform vehicle operations. The battery cable is used to provide necessary power to the electrical components, enabling vehicle operations. The method includes a step of transmitting power, ground, and signal lines between the wiring harness and the battery cable through a Master Vehicle Control Unit (MVCU) pigtail connector. This step ensures the MVCU pigtail connector effectively transmits electrical signals and power, maintaining the performance and reliability of the vehicle's electrical system.
[0054] In yet another embodiment, the present invention provides a method for maintaining a modular harness system in a vehicle. The method includes a step of inspecting the wiring harness and battery cable connections for any signs of wear or damage. This step regularly checks the integrity of the electrical connections to prevent potential failures and ensure consistent operation. The method includes a step of replacing any damaged sections of the wiring harness with modular components. The modular design of the wiring harness is utilized to easily replace faulty sections, reducing maintenance time and cost. The method includes a step of verifying the functionality of the MVCU and its connection to the wiring harness and battery cable. This step ensures the MVCU and its connections are functioning correctly to maintain optimal performance of the vehicle's electrical systems.
[0055] For different types of batteries, considering their capacity to increase the range of the vehicle, manufacturers have various SKUs. In these cases, batteries might have different connector types, and battery cables might have different wire gauges to handle various current ratings. The current flows directly from the battery to the MCU, which is part of the battery cable. By using a divided main harness, different SKUs can be managed efficiently.
[0056] In one use case, the modular harness system is implemented in one of the applicant's upcoming models, the G30 SKU vehicle. This model uses different battery packs with various MVCU pigtail connectors, such as Amphenol, Chogori, and stud-type ring terminals. Additionally, the present modular harness system utilizes a 5.4-inch TFT display with a 20-pin sealed Molex connector and a 3.3-inch display with an existing 16-pin unsealed Molex connector.
[0057] Thus, the modular harness system of the present invention provides an interconnect to assemble all three parts of the vehicle, reducing inventory costs at both the manufacturing plant and dealerships. It offers the flexibility to build multiple SKU vehicles while maintaining minimal inventory. The system simplifies the routing of the harness and requires less effort from operators at the plant and dealership. It also provides flexibility for vehicle buyers to upgrade the OEM-approved battery aftermarket to enhance the vehicle's range, by changing only minimal parts with minimal effort. The modular harness system reduces inventory costs for service centers, requiring less storage space at the plant and dealership/service center. This reduction in operator fatigue ultimately increases productivity.
[0058] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, utilized, or combined with other elements, components, or steps that are not expressly referenced.
[0059] No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0060] It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the scope of the invention. There is no intention to limit the invention to the specific form or forms enclosed. On the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the scope of the invention, as defined in the appended claims. Thus, it is intended that the present invention cover the modifications and variations of this invention, provided they are within the scope of the appended claims and their equivalents.
, Claims:I/We claim:
1. A modular harness system (100) for use with a vehicle, comprising:
a wiring harness (102) configured to distribute electrical signals and power to a plurality of electrical components within the vehicle;
a battery cable (104) configured to establish an electrical connection between a battery of the vehicle and the electrical components and supplies power to the electrical components to perform a vehicle operation; and
a Master Vehicle Control Unit (MVCU) pigtail connector (106) configured to detachably connect the wiring harness (102) and the battery cable (104).

2. The modular harness system (100) of claim 1, wherein the MVCU pigtail connector (106) comprises a plurality of pins for transmitting power, ground, and signal lines between the wiring harness (102) and the battery cable (104).

3. The modular harness system (100) of claim 1, wherein the battery cable (104) comprises: a battery cable ring terminal (104a), a battery cable Amphenol connector (104b), and a battery cable chogori connector.

4. The modular harness system (100) of claim 1, wherein the battery cable (104) is constructed with a high-gauge wire to handle the high current loads required for the vehicle operation.

5. The modular harness system (100) of claim 1, wherein the MVCU pigtail connector (106) is configured with a locking mechanism to secure the connection between the wiring harness (102) and the battery cable (104).

6. The modular harness system (100) of claim 1, wherein the wiring harness (102) and the battery cable (104) are shielded to reduce electromagnetic interference (EMI) within an electrical system of the vehicle.

7. The modular harness system (100) of claim 1, wherein the wiring harness (102) is designed in a modular way to allow for easy replacement and upgrading of individual sections of a main harness.

8. The modular harness system (100) of claim 1, wherein the MVCU pigtail connector (106) is configured to connect the wiring harness (102) to a Master Vehicle Control Unit (MVCU) (110).

9. The modular harness system (100) of claim 8, wherein the MVCU (110) comprises a microcontroller configured to process input signals from a plurality of sensors and control outputs to one or more actuators within the vehicle.

10. A method for assembling a modular harness system for a vehicle, comprising:
connecting a wiring harness to a plurality of electrical components within the vehicle;
connecting a battery cable to a battery of the vehicle; and
connecting, by using a Master Vehicle Control Unit (MVCU) pigtail connector, the wiring harness, and the battery cable.