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In response to the challenges associated with the misassembly, omission, and low manual inspection efficiency in automobile wiring harness relay assemblies, a novel online detection system has been engineered. This system consists of a mobile-based visual imaging system and an improved YOLOv5-based detection algorithm that tracks human movement to acquire images and videos. The system is coupled with deep learning for real-time detection and recognition for error-proofing the installation process of automotive wiring harness relays. This innovation aims to facilitate error-proof inspection during the assembly process of automotive wiring harness relays. The YOLOv5s model is augmented with an Adaptive Spatial Feature Fusion (ASFF) module, enhancing multi-scale feature integration capabilities. A Global Context Network (GCNet) is incorporated into the C3 module to emphasize target information from a global perspective. Additionally, the replacement of standard Convolution (Conv) modules with Global Sparse Convolution (GSConv) modules in the Neck section effectively reduces computational costs while sustaining overall performance efficacy. The experimental results show that the detection system achieved a comprehensive accuracy rate of 99.2% and an F1 score of 99.29. The system possesses high accuracy and stability, enabling flexible and intelligent target detection applications in the automotive industry. [ABSTRACT FROM AUTHOR]

A major cost, inconvenience, and source of failure for adding sensors and electronic accessories to automobiles is wiring the systems into the car's power supply. We propose an alternative approach, computer-proximal energy harvesting, which harvests power locally, so wiring is not needed. In this article, we provide an overview of the principles and empirical evaluations for harvesting energy in and around the automobile exploring the role that wind, light, vibration, and heat can play in this process. To better explore these concepts, we demonstrate two prototypes—A thermoelectric energy-based parking assistant, which is attached to the exhaust pipe, and a wind-powered external pedestrian display, which is anchored to the front bumper of a car. [ABSTRACT FROM AUTHOR]

Ergonomically unsuitable working postures are encountered in labor-intensive companies. These postures in production have a negative affect on the performance, quality, costs, and productivity. In this study, a wiring harness conveyor line was investigated in a company that performs complete wiring harness for automobiles. To evaluate the stress on the muscles caused by unsuitable postures, the AnyBody Modeling System was used. The analysis demonstrated excessively high joint reaction forces in the trunk, shoulders, arms, and legs, which can cause musculoskeletal disorders. Therefore, a new conveyor line design that can reduce the workload on operators is proposed. The working postures in the proposed design were analyzed, and the new design significantly improved the working postures. Then, the prototype conveyor line design was produced. Working postures on the produced prototype were also analyzed. The validated conveyor was manufactured, and final analyses showed that the workload on the trunk, shoulders, arms, and legs was decreased. This produced prototype is a useful example for other similar conveyor lines. [ABSTRACT FROM AUTHOR]

Warpage and volume shrinkage are important indicators of the quality of thin-walled parts during injection molding. In this study, the optimization goals are warpage and volume shrinkage. Design parameters include mold temperature, melt temperature, injection time, holding time, cooling time, and holding pressure. Based on the orthogonal experimental design and response surface experimental design, the MoldFlow software is applied to the simulation of the thin-walled part injection molding process. The importance of various parameters on warpage and volume shrinkage was analyzed by using analysis of variance. Based on the simulation results, a two-layer hidden-layer back propagation (BP) neural network model is established and the genetic algorithm (GA) is used to optimize the weights and thresholds of the back propagation neural network (BPNN) model to reduce warpage and volume shrinkage by optimizing the design parameters significantly. A support vector machine (SVM) combined with GA-BP was used to build a prediction model for predicting warpage and volume shrinkage. Taking the automobile wire harness protection frame as an example, and verified by numerical simulation, the GA-optimized two-layer hidden-layer BP neural network combination method is an effective method for injection molding to reduce warpage and volume shrinkage of thin-walled parts. SVM-BP-GA can accurately provide predictions for optimization goals; the amount of warpage and the volume shrinkage were 0.93% and 1.9%, respectively. [ABSTRACT FROM AUTHOR]

To improve the efficiency of process planning, an automotive wire harness integrated system based on CAD/CAPP platform was proposed. Firstly, each module of its functional model was described in detail. Secondly, the key technologies of system development were studied, which includes graphic database design, the method of inputting product data and the principle of process planning. Based on the AutoCAD platform and used ObjectARX software, a CAD / CAPP integrated system with C / S framework was developed. The WYSIWYG (what you see is what you get) technology was adopted to input product information, when the automobile wire harness layout was draw, both the design information of products and the handles of their corresponding drawing were stored in database. According to the technical parameters, the product data were translated into process steps and instructions, and the manufacture BOM can be automatically generated. Finally, an application instance was elaborated and the results demonstrated that the methods proposed were reasonable and valid. [ABSTRACT FROM AUTHOR]

A wire harness is a support for transferring signals or electricity. Commonly used in various branches of mechanical engineering, wiring offers more advantages than free cords and cables, that is why its rate in the automobile industry is more than 30% of the total production of cables. The paper deals with the current and future aspects regarding the manufacturing of harnesses for the automotive industry. [ABSTRACT FROM AUTHOR]

The minimal size for the conductor calculation is always the first point of interest when an electrical designer is creating a High Power Printed Circuit Board for automotive applications; in this paper you will see the factors considered to calculate the conductor size, the math information, the background information for the factors selection and the conservative rules implemented to protect the circuits for an overload; in addition this document shows two different methods to define the conductor size for the Printed Circuit Board, one based in international standards (Actual Design) and the other based in design assumptions defined to reduce the conservative rules used to calculate the conductor size (Proposal Design). In addition, you can see the validation data and the statistical results to support the implementation for the proposal method in the fuse block design used in the automotive industry, due the Proposal Design provides High Power Printed Circuit Boards with 33% less copper compared to the Actual Design. [ABSTRACT FROM AUTHOR]

Vehicular power line communication (VPLC) is being considered as a potential solution to mitigate the increase of complexity and cost of the automotive wiring harness caused by the growth of the number of electronic devices and sensors deployed inside vehicles. This is because VPLC reuses power cables for data communication and, thus, avoids the need for additional communication wires. However, this reuse does not come without problems. One of the challenges for VPLC is the time, frequency, and location dependence of the access impedance, which can cause severe impedance mismatch for the communication signal. Impedance mismatch degrades the signal-to-noise-power ratio at the communication receiver and thus affects transmission reliability. Due to the variable nature of the access impedance, a fixed matching circuit will be inefficient. Hence, in this work, we present an adaptive impedance-matching system, which improves the communication-signal transfer from the transmitting to the receiving device. The system is evaluated via simulations for a wide range of access-impedance test points and $S$- parameters of VPLC networks obtained in previous measurement campaigns. Our simulation results demonstrate that the presented adaptive matching system is able to achieve VPLC signal-power transfer within 30% of the theoretical optimum. This translates to a power gain, up to a factor of 10, which is larger than that of other solutions reported in the literature. [ABSTRACT FROM PUBLISHER]

According to the random variation of relative distances between the wires and the over-ground height of automotive wiring harness due to the different installation ways and different motion states, the crosstalk of automotive wiring harness becomes random. This paper proposes a novel statistical method of calculating random crosstalk for automotive wiring harness based on the PC (polynomial chaos) method. First, the expression of per unit of length mutual capacitance and per unit of length mutual inductance of automotive wiring harness with insulating layer are obtained by using the image method. Then, the expressions are expanded based on PC that the basis function is Legendre orthogonal polynomial. Finally, the statistical crosstalk value of automotive wiring harness can be obtained by properties of the mean and variance, which are derived from polynomial chaos. Comparing with the simulation results of MC (Monte-Carlo) method, it is demonstrated that PC method for statistical analysis of crosstalk of automotive wiring harness is reliable and efficient, and it can provide a reliable design for the arrangement of automotive wiring harness in the aspect of electromagnetic compatibility and has an important practical significance. [ABSTRACT FROM AUTHOR]

This paper presents an equivalent model for the simulation of the induced current along wiring harnesses in automobiles. The equivalent model is based on multi-transmission line theory. Then, this model is simulated by using the commercial FEM software, HFSS. The common-mode current simulation results show that the presented method is effective and the equivalent model can reduce the computation time and complexity of the wire harness model. Finally, the proposed equivalent method is proved by experiment. The equivalent model can handle automotive wiring harness for electromagnetic radiation sensitivity problems in the high frequency range. [ABSTRACT FROM AUTHOR]

The article discusses development of a lightweight electric race car by 2012 Formula Student Germany team Delft University of Technology (DUT) Racing. It cites previous participation of the team in the Formula Student Electric competition and the goal they established for 2012. The technical characteristics of the vehicle are reported including details about its regenerative power and mass distribution. The use of four identical motors to maintain simplicity of its electrical system is noted.

The electronic wedge brake is one of the brake-by-wire systems with a self-energizing effect. It is attractive because it can produce enough braking torque with the 12-voltage system. However, the electronic wedge brake cannot be implemented unless the self-energizing effect is effectively controlled. In this study, the electronic wedge brake is modeled into dynamic equations, and a sliding mode controller is designed based on the model. The clamping force is estimated based on the simplified electronic wedge brake model and the contact point detection algorithm is also provided. The performance of the proposed controller is verified in simulations and experiments using a prototype electronic wedge brake. [ABSTRACT FROM PUBLISHER]

The partial element equivalent circuit method (PEEC) is well suited to extract the conducted electromagnetic disturbances parameters from wiring systems. It provides an efficient tool for the EMC study relevant to automotive cables. However the complete EMC analysis of embedded systems requires also reliable models for the radiated emissions especially at high frequencies. In this paper a new approach based on the PEEC method and involving 3D field calculation is developed to evaluate emissions from radiating cables. [ABSTRACT FROM AUTHOR]

The replacement of automotive wiring harnesses with large-area flexible printed circuits (FPCs) would help to reduce the vehicle weight and emissions. To help clarify what a future large-area FPC interconnection harness should be capable of, a detailed design exercise to meet the engineering specification of the instrument panel wiring harness of a specific midrange passenger car was carried out. To demonstrate the added value of using an FPC, intelligence in the form of active circuitry was incorporated in the designs. Two generic architectural concepts were pursued. The first, a single large-area FPC, supported the wire harness geometry, all point-to-point interconnections, and current ratings up to 4 A. However, the panel size was too large to be manufactured on existing automotive FPC process lines. The second, intended to be a collection of smaller FPCs that could be manufactured on existing automotive FPC process lines, was found not to be practical as originally conceived. A physical implementation of the single large-area FPC design was made in stages at different company sites using various pieces of equipment, some of which are not normally used for FPC or electrical circuit manufacture. Modified versions of the equipment could be used to create a large-area automotive FPC manufacturing line. [ABSTRACT FROM AUTHOR]

This article discusses the design, implementation, and testing of a dual-path front hydrostatic drive wheel, rear caster wheel off-road vehicle. A mathematical model of the engine and major machine components was used to simulate vehicle behavior and design a drive-by-wire control system for stability and turning. The drive-by-wire system was implemented on the machine, and the model and controller were experimentally verified through testing. The physical system model contains a simplified diesel engine, hydraulic pumps and motors, gearboxes, wheels, and associated interconnecting components. The diesel engine was coupled to two hydraulic pumps via a gear box, with each hydraulic pump independently supplying flow to each hydraulic wheel motor. External disturbances were applied to the contact patch of each drive wheel. The force on each wheel was determined independently and combined to simulate vehicle acceleration, rotation, or both. A model-based controller was designed for and implemented on the machine. In the simulation, the control algorithm used steering input, speed input, and yaw rate to control pump displacement for each wheel. The controller adjusted ground drive pump displacements to maintain directional (yaw) stability when a disturbance was applied to either wheel. The controller algorithm was also implemented and verified on a test vehicle by removing the existing mechanical linkages previously used to control the hydraulic pump displacements and retrofitting electrohydraulic pump control. A joystick replaced the steering wheel and propulsion lever and was used to provide the driver inputs to the electronic controller. Testing the vehicle demonstrated positive results with stable operation up to 20 km/h (12 mph). [ABSTRACT FROM AUTHOR]