Pipeline harness guiding and fixing structure and design method thereof

Abstract

The invention relates to the technical field of vehicles, and provides a pipeline harness guiding and fixing structure and a design method thereof, and the method comprises the steps: constructing original data through first simulation software; the original data comprises pipeline harness peripheral structure data; determining a key part of the pipeline harness based on the original data and pre-obtained pipeline harness basic data; on the basis of the determined key parts of the pipeline harness and the basic data of the pipeline harness, carrying out shape-following design and simulation analysis on the pipeline harness to obtain first guiding data of the pipeline harness; the first guiding data at least comprises a space path of the pipeline harness, bending radius data and structural data of a pipeline harness guiding and fixing structure; and based on the first guiding data of the pipeline harness, constructing an initial model of the pipeline harness fixing structure through finite element simulation software, performing analysis and post-processing, and outputting target data of the optimized pipeline harness fixing structure. The interference abrasion risk of the pipe bundle and the wire harness is reduced, and stable operation of the pipe harness under the complex working condition is guaranteed.

Description

Technical Field

[0001] The present application relates to the field of vehicle technology, and in particular to a pipe harness guide and fixing structure and a design method thereof. Background Art

[0002] Patent No. CN202022842117.8 This invention patent focuses on the invention of an anti-rotation non-metallic bracket, which is used to solve the assembly convenience of non-metallic brackets. The patent focuses on the anti-rotation design of the bracket, and does not protect against wear between the pipe bundle and the wire harness and the bracket. At the same time, this bracket does not protect against mutual wear caused by the pipe bundle and the wire harness being bundled together. It only achieves weight reduction and cost reduction of non-metallic materials, and cannot effectively solve the wear problem between the pipe bundle and the wire harness.

[0003] Typically, the pipe and wiring harnesses connecting the vehicle chassis to the cab are connected to the cab body-in-white (BIW) at one end and the chassis at the other. However, due to constraints such as the vehicle's fixed structure, spatial layout, and installation method, coupled with the frequent up-and-down and left-and-right tilting of the cab relative to the chassis during driving, the cab end is in constant motion. This leads to increased wear on the pipes and wiring harnesses. Not only do the pipes and wiring harnesses interfere with each other, but they also frequently interfere with the vehicle's fixed structure, significantly increasing the risk of wear on the pipes and wiring harnesses, posing a threat to vehicle safety.

[0004] Therefore, there is an urgent need to provide a design method for a pipe harness guide and fixing structure. By analyzing and processing the pipe harness, the wear of the pipe harness can be greatly reduced during vehicle movement, effectively improving the service life of the pipe harness. Summary of the Invention

[0005] The purpose of this application is to provide a pipe and wire harness guide and fixation structure and its design method, which reduces the risk of interference wear of the pipe and wire harness, ensures the stable operation of the pipe and wire harness under complex working conditions, and significantly improves its efficiency and working cycle. The specific solution is as follows:

[0006] A method for designing a pipeline harness guide and fixing structure, the method comprising the following steps:

[0007] S1: constructing original data using a first simulation software; the original data includes peripheral structural data of the pipeline bundle;

[0008] S2: Based on the original data and pre-acquired basic data of the pipe bundle, determine the key parts of the pipe bundle; the key parts include at least: interference wear parts between the pipe bundles, and interference wear parts between the pipe bundles and surrounding structures; the basic data of the pipe bundle includes the specifications and quantity of the pipe bundle;

[0009] S3: Based on the determined key parts of the pipeline bundle and the basic data of the pipeline bundle, perform conformal design and simulation analysis on the pipeline bundle to obtain first guidance data of the pipeline bundle; the first guidance data includes at least: the spatial path of the pipeline bundle, the bending radius data, and the structural data of the pipeline bundle guide fixing structure;

[0010] S4: Based on the first guide data of the pipeline bundle, an initial model of the pipeline bundle fixing structure is constructed through finite element simulation software and analyzed and post-processed, and target data of the optimized pipeline bundle fixing structure is output, and the target data includes: structural data, stiffness data, and performance data; wherein, the optimized pipeline bundle fixing structure includes at least one large-radius pipeline bundle guide bracket and at least one pipeline bundle supporting and stabilizing bracket.

[0011] Optionally, step S2 specifically includes:

[0012] Based on the original data, identify the key parts of the pipeline bundle and the corresponding layout space;

[0013] Based on the layout space and basic data of the pipeline bundle, simulation software is used to simulate the stress distribution of the pipeline bundle under various working conditions to determine the key fixing data corresponding to the key parts of the pipeline bundle; the key fixing data at least includes the position of the fixing points and the spacing between the fixing points.

[0014] Optionally, step S3 specifically includes:

[0015] Based on the actual measurement method of pipe bundles of different specifications, the mapping relationship between pipe bundle diameter and bending radius is established;

[0016] Based on the mapping relationship between the pipe diameter and the bending radius of the pipe bundle, simulation software is used to analyze the stress distribution and wear locations of the pipe bundle under different constraints, and the key locations of the pipe bundle are redefined to match and obtain the first guidance data of the pipe bundle.

[0017] Optionally, the step S4 specifically includes:

[0018] Based on the key fixing data and the first guide data of the pipeline bundle, finite element simulation software is used for post-processing analysis to construct the target data of the pipeline bundle fixing structure;

[0019] Based on the mapping relationship between pipe diameter and bending radius, the dynamic bending range of the pipe bundle under different constraints of the vehicle is obtained;

[0020] According to the comparison result of the dynamic bending range of the pipeline bundle and the design reference value, an interference comparison method is adopted to obtain the target data of the optimized pipeline bundle fixing structure; the interference comparison method includes: a first algorithm and a second algorithm.

[0021] Optionally, the method of using an interference comparison method to obtain target data of an optimized pipe bundle fixing structure based on a comparison result of the dynamic bending range of the pipe bundle with a design reference value specifically includes:

[0022] If the difference between the upper limit and the lower limit of the dynamic bending range of the pipe bundle is greater than or equal to the design reference value, the key fixed point corresponding to the dynamic bending position of the pipe bundle is set as the motion constraint point of the pipe bundle;

[0023] Based on the difference between the upper and lower limits of the dynamic bending range and the first algorithm, a large-radius pipe harness guide bracket is designed and arranged at the pipe harness motion constraint point to constrain the pipe harness's movement path.

[0024] If the difference between the upper limit and the lower limit of the dynamic bending range of the pipe bundle is less than the design reference value, the key fixed point corresponding to the dynamic bending part of the pipe bundle is set as the pipe bundle support stabilization point;

[0025] Based on the difference between the upper and lower limits of the dynamic bending range and the second algorithm, a pipe harness support bracket is designed and placed at the pipe harness support point to cooperate with the large-radius pipe harness guide bracket to constrain the routing direction of the pipe harness.

[0026] Among them, the large-radius pipe harness guide bracket and the pipe harness supporting and stabilizing bracket cooperate together to constrain the routing direction of the pipe harness.

[0027] Optionally, the design of the large-radius pipe harness guide bracket based on the difference between the upper limit and the lower limit of the dynamic bending range and the interference comparison method specifically includes:

[0028] The first algorithm formula includes:

[0029] The difference between the inner wall curvature radius of the bracket and the minimum curvature radius of the dynamic bending of the pipe bundle is ≤ a first set value, the fit between the pipe bundle and the inner wall of the bracket is ≥ a first fit value, and the contact surface roughness of the bracket is ≤ a first roughness value;

[0030] Taking the result of the first algorithm as the optimization target, a large-radius pipe harness guide bracket is designed;

[0031] Accordingly, based on the difference between the upper and lower limits of the dynamic bending range and the interference comparison method, a stable support bracket for the pipe harness is designed, specifically including:

[0032] The second algorithm includes:

[0033] The gap between the pipe bundle and the bracket is ≤ the preset value of the pipe diameter, and the circumferential length of the bracket is ≥ the preset ratio of the straight pipe bundle length;

[0034] Taking the result of the second algorithm as the optimization target, a stable bracket for pipe bundle support is designed.

[0035] A pipe harness guide and fixation structure is applied to the method described above; the pipe harness guide and fixation structure comprises: at least one large-radius pipe harness guide bracket and at least one pipe harness support and stabilization bracket;

[0036] The large-radius pipe harness guide bracket and the pipe harness support and stabilizing bracket are spaced apart; wherein at least one of the large-radius pipe harness guide bracket and at least one of the pipe harness support and stabilizing bracket cooperate with each other to constrain the routing of the pipe harness;

[0037] At least one of the large-radius pipe and wire harness guide brackets is arranged at the dynamic bending portion of the pipe and wire harness, and is used to guide and restrain the pipe and wire harness corresponding to the dynamic bending portion;

[0038] At least one of the pipe harness support and stabilizing brackets is arranged at the straight section of the pipe harness, and is used to support and fix the pipe harness, and assist the large-radius pipe harness guide bracket to constrain the routing of the pipe harness.

[0039] Optionally, the large-radius pipe harness guide bracket includes:

[0040] A guide bracket body, wherein the guide bracket body is bent upward along the length and one side is bent backward;

[0041] A first fixing frame is integrally provided on the rear side of the guide bracket body;

[0042] Protective edges are provided on the front and rear edges of the upper surface of the guide bracket body extending upward;

[0043] Wherein, a plurality of reinforcing ribs 100 are provided on the outer sides of the two protective edges; one end of each reinforcing rib 100 is arranged on the protective edge, and the other end extends from the outer surface of the protective edge to the lower surface of the guide bracket body;

[0044] A separation rib is provided from the middle portion of the upper surface of the guide bracket body to one end; the separation rib separates one end of the upper surface of the guide bracket body into a tube bundle groove and a wire bundle groove;

[0045] One end of the upper surface of the guide bracket body is used as the pipe bundle inlet end from the pipe bundle support and stabilizing bracket; the end of the guide bracket body away from the pipe bundle support and stabilizing bracket is designed as the outlet end, and an anti-corrosion layer is matched and provided on the upper surface of the outlet end;

[0046] The guide bracket body is also provided with a pipe harness restraint portion.

[0047] Optionally, the pipe harness restraining portion includes: at least two first openings and at least two opening slots; two adjacent first openings or opening slots are arranged at intervals;

[0048] At least one of the first openings is arranged in the anti-wear layer, and at least one of the first openings is arranged at an inlet end of the upper surface;

[0049] Correspondingly, an opening slot is provided at a corresponding position of each of the protective edges to match a corresponding first opening;

[0050] It also includes a binding portion, which can pass through a corresponding first opening and a corresponding opening groove in sequence to bind the tube bundle accommodated in the tube bundle groove or the wire bundle in the wire bundle groove.

[0051] Optionally, the pipeline bundle support stabilizing bracket specifically includes:

[0052] A stabilizing bracket body, wherein the stabilizing bracket body is bent downward along the length direction;

[0053] A second fixing frame is integrally provided on the rear side of the stabilizing bracket body;

[0054] The upper surface of the stabilizing bracket body is provided with stop edges on both sides of the front and rear edges upwards;

[0055] Wherein, a plurality of reinforcing ribs are provided on the outer sides of the two stop edges; one end of each reinforcing rib is arranged on the stop edge, and the other end extends from the stop edge to the lower surface of the stabilizing bracket body;

[0056] A separation portion is provided in the longitudinal direction from the middle portion to one end of the upper surface of the stabilizing bracket body; the separation portion separates the upper surface of the stabilizing bracket body into a tube bundle groove and a wire bundle groove;

[0057] The stabilizing bracket body is also provided with a pipe harness fixing portion.

[0058] Compared with the prior art, the present invention has the following beneficial effects:

[0059] The present invention provides a pipe harness guide fixing structure and a design method thereof; by constructing original data and combining it with the basic data of the pipe harness to accurately locate key parts, and through conformal design, simulation analysis and finite element processing, output optimized target data. Based on the differences in the dynamic bending range of the pipe harness, the interference comparison method is used to specifically design a large-radius pipe harness guide bracket and a pipe harness support stabilization bracket, which cooperate to constrain the routing direction. The bracket parameters are accurately set using an algorithm to ensure compatibility with the pipe harness. This design effectively reduces the risk of interference wear of the pipe harness and the harness, avoids excessive bending and wear of the pipe harness due to vehicle movement, ensures its stable operation under complex working conditions, significantly improves its efficiency and working cycle, and enhances vehicle safety and reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 A flow chart of a design method for a pipe harness guide and fixing structure provided by the present invention;

[0061] Figure 2 This is a schematic diagram of the structure of the large-radius pipe harness guide bracket;

[0062] Figure 3 Schematic diagram of the structure of the bracket that supports the pipe harness;

[0063] Figure 4 This is a schematic diagram of the structure of the large rounded pipe harness guide bracket from another angle;

[0064] Figure 5 A schematic diagram of the structure of the bracket supporting the pipe harness from another angle;

[0065] In the picture:

[0066] 1. Large rounded pipe harness guide bracket;

[0067] 10. Guide bracket body;

[0068] 11. First fixing frame; 110. Weight reduction slot; 111. Stabilizing arm; 112. Triangular plate;

[0069] 12. Protective edge; 13. Separation rib; 14. Anti-corrosion layer; 15. First opening; 16. Opening groove;

[0070] 2. Pipeline harness support and stable bracket;

[0071] 20. Stabilize the bracket body;

[0072] 21. Second fixing bracket; 210. Angle plate; 211. Angle iron;

[0073] 22. Stop edge; 23. Separation portion; 24. Constraint hole; 25. Constraint groove;

[0074] 100. Strengthen the ribs. DETAILED DESCRIPTION

[0075] In order to make the purpose, technical solutions and advantages of this application clearer, the following Figure 1-5 This application is further described in detail. Obviously, the embodiments described are only a part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0076] The terms used in the examples of this application are for the purpose of describing specific embodiments only and are not intended to limit this application. The singular forms "a," "the," and "the" used in the examples of this application and the appended claims are also intended to include plural forms, and unless the context clearly indicates otherwise, "a plurality" generally includes at least two.

[0077] It should be understood that the term "and / or" as used herein is merely a description of the relationship between associated objects, indicating that three possible relationships exist. For example, "A and / or B" can represent: A exists alone, A and B exist simultaneously, or B exists alone. Furthermore, the character " / " in this document generally indicates that the associated objects are in an "or" relationship.

[0078] It should be understood that although the terms first, second, third, etc. may be used to describe in the embodiments of the present application, these descriptions should not be limited to these terms. These terms are only used to distinguish the descriptions. For example, without departing from the scope of the embodiments of the present application, the first may also be referred to as the second, and similarly, the second may also be referred to as the first.

[0079] As used herein, the words "if" and "if" may be interpreted as "at the time of" or "when" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrases "if it is determined" or "if (stated condition or event) is detected" may be interpreted as "when it is determined" or "in response to the determination" or "when detecting (stated condition or event)" or "in response to detecting (stated condition or event)," depending on the context.

[0080] It should also be noted that the terms "include," "comprises," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a product or device comprising a series of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such product or device. In the absence of further limitations, an element defined by the phrase "comprises a..." does not exclude the presence of other identical elements in the product or device comprising the element.

[0081] It should be noted in particular that any symbols and / or numbers in the specification that are not marked in the accompanying drawings are not drawing marks.

[0082] like Figure 1 A design method for a pipeline harness guide and fixing structure is shown, the method comprising the following steps:

[0083] S1: constructing original data using a first simulation software; the original data includes peripheral structural data of the pipeline bundle;

[0084] S2: Based on the original data and pre-acquired basic data of the pipe bundle, determine the key parts of the pipe bundle; the key parts include at least: interference wear parts between the pipe bundles, and interference wear parts between the pipe bundles and surrounding structures; the basic data of the pipe bundle includes the specifications and quantity of the pipe bundle;

[0085] S3: Based on the determined key parts of the pipeline bundle and the basic data of the pipeline bundle, perform conformal design and simulation analysis on the pipeline bundle to obtain first guidance data of the pipeline bundle; the first guidance data includes at least: the spatial path of the pipeline bundle, the bending radius data, and the structural data of the pipeline bundle guide fixing structure;

[0086] S4: Based on the first guide data of the pipeline bundle, an initial model of the pipeline bundle fixing structure is constructed through finite element simulation software and analyzed and post-processed, and the target data of the optimized pipeline bundle fixing structure is output, and the target data includes: structural data, stiffness data, and performance data; wherein, the optimized pipeline bundle fixing structure includes at least one large-radius pipeline bundle guide bracket 1 and at least one pipeline bundle support and stabilization bracket 2.

[0087] Specifically, this application first constructs a raw data model. By analyzing the surrounding structural data of the pipe and wiring harness, the specifications and quantity of the pipe and wiring harness are fully considered during the pipe and wiring harness layout process, and the key locations suitable for pipe and wiring harness layout are preliminarily identified. Through conformal design, simulation analysis, and finite element processing, optimized target data is output, allowing for the targeted design of a large-radius pipe and wiring harness guide bracket 1 and a pipe and wiring harness support and stabilization bracket 2. An algorithm is used to precisely set the bracket parameters to ensure compatibility with the pipe and wiring harness. This effectively reduces the risk of interference wear between the pipe and wiring harness, and avoids interference wear between the pipe and wiring harness caused by vehicle movement.

[0088] In a specific embodiment, the key parts of the pipeline bundle are determined based on the original data and the pre-acquired basic data of the pipeline bundle. The key parts include at least: interference wear parts between the pipeline bundles, and interference wear parts between the pipeline bundles and surrounding structures. The basic data of the pipeline bundle includes the specifications and quantity of the pipeline bundle, specifically including:

[0089] Based on the original data, identify the key parts of the pipeline bundle and the corresponding layout space;

[0090] Based on the layout space and basic data of the pipeline bundle, simulation software is used to simulate the stress distribution of the pipeline bundle under various working conditions to determine the key fixing data corresponding to the key parts of the pipeline bundle; the key fixing data at least includes the position of the fixing points and the spacing between the fixing points.

[0091] For example, in the design of a heavy truck chassis pipe harness, CATIA software was used to build the original geometric model of the pipe harness and surrounding structures (frame, suspension components, etc.), and basic data such as the pipe harness specifications (diameter 12mm, material PVC insulation layer), quantity (20 groups), etc. were obtained. A dynamic model was established using ADAMS software to simulate the truck on bumpy roads (speed 30km / h, road roughness grade C), sudden braking (deceleration 3m / s 2 ) and sharp turns (lateral acceleration of 0.4g). Simulation results show that under bumpy conditions, stress concentration is significant at the contact point between the pipe harness and the frame crossbar, reaching 8MPa (exceeding the material's allowable stress of 5MPa); under sharp turns, the stress at the bend of the pipe harness reaches 7.5MPa. Based on this, it was determined that fixed points should be set every 250mm at the stress concentration point to reduce the maximum stress to 4.5MPa. Bench tests verified that the wear of the pipe harness after 100,000 cycles of loading was only 0.05mm, far lower than the 0.3mm of the unoptimized design.

[0092] In a specific embodiment, S3: Based on the determined key parts of the pipeline bundle and the basic data of the pipeline bundle, the pipeline bundle is subjected to conformal design and simulation analysis to obtain first guidance data of the pipeline bundle; the first guidance data includes at least: the spatial path of the pipeline bundle, the bending radius data, and the structural data of the pipeline bundle guide fixing structure, specifically including:

[0093] Based on the actual measurement method of pipe bundles of different specifications (such as using tensile testing machines, angle measuring instruments, etc. to apply bending loads to pipe bundles of different specifications and measure their bending radius), a mapping relationship between pipe bundle diameter and bending radius is established to clarify the natural bending characteristics of the pipe bundle in an undamaged state;

[0094] Based on the mapping relationship between pipe diameter and bending radius, simulation software was used to analyze the stress distribution and wear locations of the pipe bundle under different constraints. Key locations of the pipe bundle were redefined to match the first guidance data of the pipe bundle. The different constraints included at least vibration load constraints, temperature load constraints, and dynamic bending load constraints.

[0095] For example, the constructed mapping relationship was imported into ANSYS Workbench, and vibration load constraints were set to simulate random vibration with a frequency of 20-200Hz and an acceleration amplitude of 1g during vehicle operation. Temperature load constraints, such as the battery pack operating temperature range of -20°C to 50°C, and dynamic bending load constraints were set to simulate the dynamic bending of the wiring harness during rapid acceleration and deceleration of the vehicle. Simulation results showed that under the coupled dynamic bending and temperature loads, stress concentration occurred at the connection between the wiring harness and the battery pack mounting bracket, which was previously unidentified. The stress value reached 8MPa, exceeding the material's allowable stress of 6MPa. Therefore, this area was redefined as a critical part.

[0096] In a specific embodiment, step S4: based on the first guide data of the pipeline bundle, an initial model of the pipeline bundle fixing structure is constructed using finite element simulation software and analyzed and post-processed, and target data of the optimized pipeline bundle fixing structure is output, wherein the target data includes: structural data, stiffness data, and performance data; wherein the optimized pipeline bundle fixing structure includes at least one large-radius pipeline bundle guide bracket 1 and at least one pipeline bundle support and stabilization bracket 2, specifically including:

[0097] Based on the key fixing data and the first guide data of the pipeline bundle, finite element simulation software is used for post-processing analysis to construct the target data of the pipeline bundle fixing structure;

[0098] Based on the mapping relationship between pipe diameter and bending radius, the dynamic bending range of the pipe bundle under different constraints of the vehicle is obtained;

[0099] According to the comparison result of the dynamic bending range of the pipeline bundle and the design reference value, an interference comparison method is adopted to obtain the target data of the optimized pipeline bundle fixing structure; the interference comparison method includes: a first algorithm and a second algorithm.

[0100] It can be understood that by simulating different working conditions of the vehicle during driving, the bending conditions of the pipe harness will also change accordingly. It is necessary to focus on these dynamic changes to optimize the fixed structure, so as to reasonably constrain the layout of the pipe harness and reduce the interference wear of the pipe harness as much as possible. At the same time, it avoids the problem that the pipe harness is easily damaged due to improper bending in a dynamic environment, thereby extending the service life of the pipe harness.

[0101] For example, simulation software was used to construct an initial model of the harness's mounting structure using primary guidance data, such as the harness's spatial path, bend radius, and key fixture information. Material properties for the non-metallic bracket were defined, such as an elastic modulus of 2 GPa and a Poisson's ratio of 0.3. Simulating vehicle vibration conditions during driving revealed stress concentration at the bracket joints, reaching 8 MPa, exceeding the material's allowable value.

[0102] Furthermore, the interference comparison method is used to obtain target data of the optimized pipe bundle fixing structure based on the comparison result of the dynamic bending range of the pipe bundle with the design reference value, which specifically includes:

[0103] If the difference between the upper limit and the lower limit of the dynamic bending range of the pipe bundle is greater than or equal to the design reference value, the key fixed point corresponding to the dynamic bending position of the pipe bundle is set as the motion constraint point of the pipe bundle;

[0104] Based on the difference between the upper limit and the lower limit of the dynamic bending range and the first algorithm, a large-radius pipe harness guide bracket 1 is designed, and the large-radius pipe harness guide bracket 1 is arranged at the pipe harness motion constraint point to limit the movement path of the pipe harness;

[0105] If the difference between the upper limit and the lower limit of the dynamic bending range of the pipe bundle is less than the design reference value, the key fixed point corresponding to the dynamic bending part of the pipe bundle is set as the pipe bundle support stabilization point;

[0106] Based on the difference between the upper and lower limits of the dynamic bending range and the second algorithm, a pipe bundle support stabilizing bracket 2 is designed and placed at the pipe bundle support stabilizing point to cooperate with the large-radius pipe bundle guide bracket 1 to jointly constrain the routing direction of the pipe bundle.

[0107] The large-radius pipe harness guide bracket 1 cooperates with the pipe harness support and stabilization bracket 2 to constrain the routing direction of the pipe harness.

[0108] Furthermore, the design of the large-radius pipe harness guide bracket 1 based on the difference between the upper limit and the lower limit of the dynamic bending range and the interference comparison method specifically includes:

[0109] The first algorithm formula includes:

[0110] The difference between the inner wall curvature radius of the bracket and the minimum curvature radius of the dynamic bending of the pipe bundle is ≤ a first set value, the fit between the pipe bundle and the inner wall of the bracket is ≥ a first fit value, and the contact surface roughness of the bracket is ≤ a first roughness value;

[0111] Taking the result of the first algorithm as the optimization target, a large-radius pipe harness guide bracket 1 is designed;

[0112] Accordingly, based on the difference between the upper limit and the lower limit of the dynamic bending range and the interference comparison method, the pipeline harness support stabilizing bracket 2 is designed, specifically including:

[0113] The second algorithm includes:

[0114] The gap between the pipe bundle and the bracket is ≤ the preset value of the pipe diameter, and the circumferential length of the bracket is ≥ the preset ratio of the straight pipe bundle length;

[0115] Taking the result of the second algorithm as the optimization target, the pipeline bundle support stabilizing bracket 2 is designed.

[0116] For example, in the design of an electric vehicle battery pack harness, finite element simulation revealed that the dynamic bending range of a certain high-voltage harness under conditions such as rapid vehicle acceleration was 120-170mm, compared to a design reference value of 25mm. Because this difference exceeded the design reference, the key fixed point corresponding to the harness's dynamic bending location was designated as a motion constraint. Based on a first algorithm, the first setpoint was set to 15mm, the first fit value to 85%, and the first roughness to 1.0μm. After calculation and optimization, the difference between the inner wall curvature radius of the designed large-radius harness guide bracket 1 and the minimum curvature radius for dynamic bending was 12mm, achieving a 90% fit between the harness and the bracket's inner wall, and a surface roughness of 0.8μm. Simulations verified that the bracket's placement at the motion constraint effectively restricted the harness's movement path, reducing stress concentration by 30%, thereby effectively avoiding interference wear between the harness and the bracket, between the harness and surrounding structures, and between the harness and surrounding structures.

[0117] It should be noted that the design of the non-metallic guide fixing structure does not have the problem of rust, which solves the rust caused by long-term rain and sun exposure, and improves the aesthetics and quality. In order to ensure the basic function of the bracket, the reinforcement rib design is used to ensure that the rigidity and strength of the guide fixing structure meet the requirements of pipe harness fixation. The flange design, such as the protective edge 12, ensures that the bracket assembly is anti-rotation, improves the convenience of assembly, and can also take into account the improvement of structural strength. Considering the weather resistance of non-metallic materials to the environment, the non-metallic formula is formulated and tested in the environmental chamber to ensure that it can meet the invariance from low temperature of -40°C to high temperature of 40°C, and the rigidity and strength can be guaranteed.

[0118] It can be understood that the design method of a pipe harness guiding and fixing structure provided by the present application reduces interference wear, reduces the probability of damage to the pipe harness due to wear, extends its service life during the operation of the vehicle or other equipment, reduces maintenance costs and replacement frequency. At the same time, according to the actual dynamic bending conditions of the pipe harness, different algorithms are used to design the bracket to ensure that the bracket parameters are highly adapted to the characteristics of the pipe harness, avoiding problems such as loose fixation or excessive constraint of the pipe harness due to unreasonable fixing structure.

[0119] On the other hand, the present application provides a pipe harness guide and fixing structure, which is applied to the method described above; the pipe harness guide and fixing structure comprises: at least one large-radius pipe harness guide bracket 1 and at least one pipe harness support and stabilization bracket 2;

[0120] The large-radius pipe harness guide bracket 1 is spaced apart from the pipe harness support and stabilization bracket 2; wherein at least one of the large-radius pipe harness guide bracket 1 cooperates with at least one of the pipe harness support and stabilization bracket 2 to support the pipe harness to constrain the routing of the pipe harness;

[0121] At least one of the large-radius pipe harness guide brackets 1 is arranged at the dynamic bending portion of the pipe harness, and is used to guide and restrain the pipe harness corresponding to the dynamic bending portion;

[0122] At least one of the pipe harness support and stabilizing brackets 2 is arranged at the straight section of the pipe harness, and is used to support and fix the pipe harness, and assist the large-radius pipe harness guide bracket 1 to constrain the routing of the pipe harness.

[0123] Specifically, the large-radius pipe guide bracket 1 and the pipe support bracket 2 work together to constrain the pipe bundle's range of motion, ensuring that the pipe bundle follows a pre-set path and preventing interference with each other or with surrounding structures. This further reduces friction and wear between the pipe bundle and the bracket, lowering the risk of pipe failure due to mechanical damage. The large-radius design and strict surface roughness control further minimize damage to the pipe bundle's outer protective layer, extending the pipe bundle's service life.

[0124] Furthermore, the large-radius pipe harness guide bracket 1 includes:

[0125] A guide bracket body 10, wherein the guide bracket body 10 is bent upward along the length direction and one side is bent backward;

[0126] A first fixing frame 11 is integrally provided on the rear side of the guide bracket body 10 ; the guide bracket body 10 can be connected and fixed to the surrounding structure via the first fixing frame 11 .

[0127] The first fixing frame 11 is approximately an open-shaped structure as a whole; wherein the upper part of the first fixing frame 11 matches the outer contour of the guide bracket main body 10, and a weight-reducing groove 110 is provided on the upper part of the first fixing frame 11; the edges on both sides of the middle part of the first fixing frame 11 are bent forward and extended to have stabilizing arms 111, and the overall connection strength of the guide bracket main body 10 is further reinforced by the stabilizing arms 111; a triangular plate 112 is provided on the front end surface of the first fixing frame 11 between the two stabilizing arms 111, and the triangular plate 112 further expands the overall strength and rigidity of the guide bracket main body 10, and has a higher anti-vibration effect.

[0128] The upper surface of the guide bracket body 10 is provided with protective edges 12 on both sides of the front and rear edges.

[0129] Among them, several reinforcing ribs 100 are provided on the outer sides of the two protective edges 12; one end of each reinforcing rib 100 is arranged on the protective edge 12, and the other end extends from the outer surface of the protective edge 12 to the lower surface of the guide bracket body 10 to increase the strength and rigidity of the guide bracket body 10.

[0130] A separation rib 13 is provided in the length direction from the middle part to one end of the upper surface of the guide bracket body 10; the separation rib 13 separates one end of the upper surface of the guide bracket body 10 into a tube bundle groove and a wire harness groove to separate the tube bundle and the wire harness, thereby fundamentally avoiding interference wear between the tube bundle and the wire harness, and facilitating subsequent maintenance and inspection.

[0131] One end of the upper surface of the guide bracket body 10 serves as the inlet end of the pipe bundle from the pipe bundle supporting and stabilizing bracket 2; the end of the guide bracket body 10 away from the pipe bundle supporting and stabilizing bracket 2 is designed as the outlet end, and an anti-corrosion layer 14 is matched on the upper surface of the outlet end to reduce the wear between the pipe bundle and the guide bracket body and extend the service life of the pipe bundle.

[0132] The guide bracket body is also provided with a pipe and wire harness restraining portion, which can restrain the pipe and wire harness in the pipe harness groove and the wire harness groove to prevent it from escaping.

[0133] Furthermore, the pipe harness restraining portion includes: at least two first openings 15 and at least two opening slots 16; two adjacent first openings 15 or opening slots 16 are arranged at intervals;

[0134] At least one of the first openings 15 is arranged in the anti-wear layer, and at least one of the first openings 15 is arranged at the inlet end of the upper surface;

[0135] Correspondingly, an opening slot 16 is provided at a corresponding position of each of the protective edges 12 to match a corresponding first opening 15;

[0136] It also includes a binding portion, which can pass through a corresponding first opening 15 and a corresponding opening slot 16 in sequence to bind the tube bundle accommodated in the tube bundle slot or the wire bundle in the wire bundle slot, for example, a tube bundle clamp.

[0137] Furthermore, the pipeline harness support stabilizing bracket 2 specifically includes:

[0138] A stabilizing bracket body 20, wherein the stabilizing bracket body 20 is bent downward along its length;

[0139] A second fixing frame 21 is integrally provided on the rear side of the stable bracket body 20; a corner plate 210 is provided on the front end face of the middle part of the second fixing frame 21; the corner plate 210 connects and reinforces the second fixing frame 21 and the stable bracket body 20; a plurality of angle irons 211 are provided on the top of the second fixing frame 21, which is connected and fixed to the stable bracket body 20 through the plurality of angle irons 211.

[0140] The upper surface of the stabilizing bracket body 20 is provided with stop edges 22 on both sides of the front and rear edges.

[0141] The outer sides of the two stop edges 22 are each provided with a plurality of reinforcing ribs 100 ; one end of each reinforcing rib 100 is arranged on the stop edge 22 , and the other end extends from the stop edge 22 to the lower surface of the stabilizing bracket body 20 ;

[0142] A separation portion 23 is provided in the longitudinal direction from the middle portion to one end of the upper surface of the stabilizing bracket body 20; the separation portion 23 separates the upper surface of the stabilizing bracket body 20 into a tube harness groove and a wire harness groove;

[0143] The said stable support body 20 is also provided with a pipe harness fixing portion. The said pipe harness restraining portion comprises: a plurality of pairs of matching restraining holes 24 and restraining grooves 25;

[0144] Each restraining hole 24 is arranged at the center of the stabilizing bracket body 20 , and the corresponding restraining groove 25 is correspondingly provided on the stop edge 22 .

[0145] By using a cable tie, passing through the corresponding restraining holes 24 and restraining grooves 25, the pipes and wire harnesses in the pipe harness groove and the wire harness groove are restrained.

[0146] It can be understood that the present application realizes the arrangement of the guide routing of the pipe bundle by cooperating with the large-radius pipe bundle guide bracket 1 and the pipe bundle support and stabilization bracket 2. In actual design, the structure, quantity, layout position and layout spacing of the pipe bundle guide and fixed structure can be calculated according to the design method of the pipe bundle guide and fixed structure, thereby reducing the interference wear between the pipe bundles, between the pipe bundle and the bracket, or between the pipe bundle and the surrounding structure, and effectively extending the utilization efficiency of the pipe bundle.

[0147] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A design method for a pipe harness guide and fixing structure, characterized in that: The method comprises the following steps: S1: constructing original data using a first simulation software; the original data includes peripheral structural data of the pipeline bundle; S2: Based on the original data and pre-acquired basic data of the pipe bundle, determine the key parts of the pipe bundle; the key parts include at least: interference wear parts between the pipe bundles, and interference wear parts between the pipe bundles and surrounding structures; the basic data of the pipe bundle includes the specifications and quantity of the pipe bundle; S3: Based on the determined key parts of the pipeline bundle and the basic data of the pipeline bundle, perform conformal design and simulation analysis on the pipeline bundle to obtain first guidance data of the pipeline bundle; the first guidance data includes at least: the spatial path of the pipeline bundle, the bending radius data, and the structural data of the pipeline bundle guide fixing structure; S4: Based on the first guide data of the pipeline bundle, an initial model of the pipeline bundle fixing structure is constructed through finite element simulation software and analyzed and post-processed, and target data of the optimized pipeline bundle fixing structure is output, and the target data includes: structural data, stiffness data, and performance data; wherein, the optimized pipeline bundle fixing structure includes at least one large-radius pipeline bundle guide bracket and at least one pipeline bundle supporting and stabilizing bracket.

2. The method according to claim 2, characterized in that Step S2 specifically includes: Based on the original data, identify the key parts of the pipeline bundle and the corresponding layout space; Based on the layout space and basic data of the pipeline bundle, simulation software is used to simulate the stress distribution of the pipeline bundle under various working conditions to determine the key fixing data corresponding to the key parts of the pipeline bundle; the key fixing data at least includes the position of the fixing points and the spacing between the fixing points.

3. The method according to claim 2, characterized in that The step S3 specifically includes: Based on the actual measurement method of pipe bundles of different specifications, the mapping relationship between pipe bundle diameter and bending radius is established; Based on the mapping relationship between the pipe diameter and the bending radius of the pipe bundle, simulation software is used to analyze the stress distribution and wear locations of the pipe bundle under different constraints, and the key locations of the pipe bundle are redefined to match and obtain the first guidance data of the pipe bundle.

4. The method according to claim 3, characterized in that The step S4 specifically includes: Based on the key fixing data and the first guide data of the pipeline bundle, finite element simulation software is used for post-processing analysis to construct the target data of the pipeline bundle fixing structure; Based on the mapping relationship between pipe diameter and bending radius, the dynamic bending range of the pipe bundle under different constraints of the vehicle is obtained; According to the comparison result of the dynamic bending range of the pipeline bundle and the design reference value, an interference comparison method is adopted to obtain the target data of the optimized pipeline bundle fixing structure; the interference comparison method includes: a first algorithm and a second algorithm.

5. The method according to claim 4, characterized in that The interference comparison method is used to obtain target data of the optimized pipe harness fixing structure based on the comparison result of the dynamic bending range of the pipe harness and the design reference value, which specifically includes: If the difference between the upper limit and the lower limit of the dynamic bending range of the pipe bundle is greater than or equal to the design reference value, the key fixed point corresponding to the dynamic bending position of the pipe bundle is set as the motion constraint point of the pipe bundle; Based on the difference between the upper and lower limits of the dynamic bending range and the first algorithm, a large-radius pipe harness guide bracket is designed and arranged at the pipe harness motion constraint point to constrain the pipe harness's movement path. If the difference between the upper limit and the lower limit of the dynamic bending range of the pipe bundle is less than the design reference value, the key fixed point corresponding to the dynamic bending part of the pipe bundle is set as the pipe bundle support stabilization point; Based on the difference between the upper and lower limits of the dynamic bending range and the second algorithm, a pipe harness support bracket is designed and placed at the pipe harness support point to cooperate with the large-radius pipe harness guide bracket to constrain the routing direction of the pipe harness. Among them, the large-radius pipe harness guide bracket and the pipe harness supporting and stabilizing bracket cooperate together to constrain the routing direction of the pipe harness.

6. The method according to claim 5, characterized in that The design of the large-radius pipe harness guide bracket based on the difference between the upper limit and the lower limit of the dynamic bending range and the interference comparison method specifically includes: The first algorithm formula includes: The difference between the inner wall curvature radius of the bracket and the minimum curvature radius of the dynamic bending of the pipe bundle is ≤ a first set value, the fit between the pipe bundle and the inner wall of the bracket is ≥ a first fit value, and the contact surface roughness of the bracket is ≤ a first roughness value; Taking the result of the first algorithm as the optimization target, a large-radius pipe harness guide bracket is designed; Accordingly, based on the difference between the upper and lower limits of the dynamic bending range and the interference comparison method, a stable support bracket for the pipe harness is designed, specifically including: The second algorithm includes: The gap between the pipe bundle and the bracket is ≤ the preset value of the pipe diameter, and the circumferential length of the bracket is ≥ the preset ratio of the straight pipe bundle length; Taking the result of the second algorithm as the optimization target, a stable bracket for pipe bundle support is designed.

7. A pipe harness guide and fixing structure, characterized in that: The method according to any one of claims 1 to 6; the pipe harness guide and fixing structure comprises: at least one large-radius pipe harness guide bracket (1) and at least one pipe harness support and stabilizing bracket (2); The large-radius pipe harness guide bracket (1) and the pipe harness support and stabilizing bracket (2) are spaced apart; wherein at least one of the large-radius pipe harness guide bracket (1) cooperates with at least one of the pipe harness support and stabilizing bracket (2) to constrain the routing arrangement of the pipe harness; At least one large-radius pipe harness guide bracket (1) is arranged at a dynamic bending portion of the pipe harness and is used to guide and restrain the pipe harness corresponding to the dynamic bending portion; At least one of the pipe harness support and stabilizing brackets (2) is arranged at the straight section of the pipe harness, and is used to support and fix the pipe harness, and assist the large-radius pipe harness guide bracket (1) in constraining the routing of the pipe harness.

8. The pipeline harness guiding and fixing structure according to claim 7, characterized in that: The large-radius pipe harness guide bracket (1) comprises: A guide bracket body (10), wherein the guide bracket body (10) is bent upward along the length direction and one side is bent inward; A first fixing frame (11) is integrally provided on the rear side of the guide bracket body (10); Protective edges (12) are provided on the front and rear edges of the upper surface of the guide bracket body (10) extending upward; Wherein, a plurality of reinforcing ribs are provided on the outer sides of the two protective edges (12); one end of each reinforcing rib is arranged on the protective edge (12), and the other end extends from the outer surface of the protective edge (12) to the lower surface of the guide bracket body (10); A separation rib (13) is provided in the longitudinal direction from the middle portion to one end of the upper surface of the guide bracket body (10); the separation rib (13) separates one end of the upper surface of the guide bracket body (10) into a tube bundle groove and a wire bundle groove; One end of the upper surface of the guide bracket body (10) serves as the pipe bundle inlet end of the self-pipe bundle supporting and stabilizing bracket (2); the end of the guide bracket body (10) away from the pipe bundle supporting and stabilizing bracket (2) is designed as the outlet end, and an anti-corrosion layer (14) is matched and provided on the upper surface of the outlet end; The guide bracket main body (10) is also provided with a pipe harness restraining portion.

9. The pipeline harness guiding and fixing structure according to claim 8, characterized in that: The pipe harness restraining portion comprises: at least two first openings (15) and at least two opening slots (16); two adjacent first openings (15) or opening slots (16) are arranged at intervals; At least one of the first openings (15) is arranged in the anti-wear layer, and at least one of the first openings (15) is arranged at the inlet end of the upper surface; Correspondingly, an opening slot (16) is provided at a corresponding position of each of the protective edges (12) and matches a corresponding first opening (15); It also includes a binding portion, which can pass through a corresponding first opening (15) and a corresponding opening slot (16) in sequence to bind the tube bundle accommodated in the tube bundle slot or the wire bundle in the wire bundle slot.

10. The pipeline harness guiding and fixing structure according to claim 9, characterized in that: The pipeline harness supporting and stabilizing bracket (2) specifically comprises: A stabilizing bracket body (20), wherein the stabilizing bracket body (20) is bent downward along the length direction; A second fixing frame (21) is integrally provided on the rear side of the stabilizing bracket body (20); Stop edges (22) are provided on the front and rear edges of the upper surface of the stabilizing bracket body (20) facing upwards; Wherein, a plurality of reinforcing ribs are provided on the outer sides of the two stop edges (22); one end of each reinforcing rib is arranged on the stop edge (22), and the other end extends from the stop edge (22) to the lower surface of the stabilizing bracket body (20); A separation portion (23) is provided in the longitudinal direction from the middle portion to one end of the upper surface of the stabilizing bracket body (20); the separation portion (23) separates the upper surface of the stabilizing bracket body (20) into a tube bundle groove and a wire bundle groove; The stabilizing bracket body (20) is also provided with a pipe harness fixing portion.

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