Wire harness structure capable of adaptively adjusting tension

Abstract

The utility model discloses a wire harness structure capable of self-adaptively adjusting tension, which comprises a lead and joints, a tensioning mechanism is arranged on the lead, the joints are fixedly arranged at the front end and the rear end of the lead, the tensioning mechanism comprises a tensioning box, a sliding block, a spring and a pulley, two groups of parallel damping sliding chutes are arranged on the upper end surface of the tensioning box, and the two groups of damping sliding chutes are arranged in parallel. The sliding block and the spring are installed in the damping sliding groove and slidably connected with the tensioning box, the pulley is installed on the sliding block and rotatably connected with the sliding block, and the wire is wound on the pulley and slidably connected with the pulley. The wire harness tension adjusting device has the advantages of automatically adjusting tension, preventing the wire harness from loosening and drooping and prolonging the service life, and solves the problems of abrasion, breakage and unstable connection caused by length redundancy or environmental vibration of a traditional wire harness.

Description

Technical Field

[0001] This utility model relates to the field of wire harness technology, specifically to a wire harness structure that adaptively adjusts tension. Background Technology

[0002] In modern industrial equipment, automation systems, and transportation vehicles, wire harnesses, as a crucial component of electrical connections, are widely used in various control circuits and power transmission systems. Traditional wire harness structures typically consist of wires and connectors, with wiring methods often involving direct straightening or simple fixing, lacking an effective mechanism for adjusting wire harness tension. When the wire harness length slightly exceeds the installation space, it is prone to slack and sagging, causing friction between the harness and other mechanical components, leading to insulation wear and even wire breakage, posing significant safety hazards.

[0003] Furthermore, existing wire harness structures often fail to achieve dynamic adaptive tension adjustment when facing complex operating conditions such as environmental vibration, temperature changes, or mechanical displacement, thus affecting the stability and reliability of electrical connections. Especially in high-vibration or frequent-motion applications (such as robots and rail transit equipment), the problem of fatigue damage caused by uneven stress on the wire harness is particularly prominent. Therefore, an adaptive tension-adjusting wire harness structure is needed to solve these problems. Summary of the Invention

[0004] The purpose of this invention is to provide a wire harness structure with adaptive tension adjustment, which has the advantages of automatically adjusting tension, preventing wire harness slack and sagging, and improving service life. It solves the problems of wear, breakage and unstable connection caused by length redundancy or environmental vibration in traditional wire harnesses.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an adaptive tension-adjustable wire harness structure, comprising a wire and a connector, wherein a tensioning mechanism is provided on the wire;

[0006] The connector is fixedly installed at both ends of the conductor. The tensioning mechanism includes a tensioning box, a slider, a spring, and a pulley. The upper end face of the tensioning box is provided with two sets of mutually parallel damping grooves. The slider and spring are installed in the damping grooves and are slidably connected to the tensioning box. The pulley is installed on the slider and is rotatably connected to it. The conductor is wound on the pulley and is slidably connected to it.

[0007] Furthermore, the slider has a roller rotatably connected to its side end face, and a positioning post that cooperates with the spring on the side end face of the slider.

[0008] Furthermore, the upper end face of the slider is provided with a rotating shaft, the center of the pulley is provided with a shaft hole that mates with the rotating shaft, and the upper and lower ends of the outer end face of the pulley are provided with limit flanges.

[0009] Furthermore, the wire has a flat structure.

[0010] Furthermore, the upper surface of the tensioning box is provided with a threading groove, and the side wall of the threading groove is provided with a dustproof curtain, which is made of silicone material.

[0011] Furthermore, a magnet is provided on the front end face of the tensioning box, and a magnetic groove corresponding to the position of the magnet is provided on the back side of the tensioning box.

[0012] Furthermore, the outer end face of the connector is provided with a rotatable internal thread cap.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0014] This invention achieves dynamic adjustment of wire harness tension through the coordinated design of the slider, spring, and pulley assembly within the tensioning box, combined with the "S"-shaped winding method of the wire. When the wire becomes too long and slack, the spring pushes the slider to slide along the damping groove, automatically storing the excess wire harness in the tensioning box. This prevents friction with other components or wear on the insulation layer caused by the excessive length of the cable. The flat wire design further optimizes this effect; its horizontally flexible characteristics facilitate winding onto the pulley, while its longitudinal bending resistance reduces the risk of falling due to its own weight. This structure fundamentally solves the safety hazards caused by redundant length in traditional wire harnesses and significantly improves service life.

[0015] This invention reduces frictional resistance with the tensioning box through the roller structure of the slider, and ensures smooth slider movement and uniform force distribution by combining the precise guidance of the spring by the positioning post, thus avoiding jamming. The limiting flange on the pulley effectively constrains the position of the wire, preventing entanglement and deviation that could lead to tension failure. At the same time, the rotating connection design of the internal thread cap at the joint prevents the joint from loosening during tensioning through the thread self-locking effect, ensuring the overall stability of the wire harness connection. These structures work together to ensure the reliability of the tension adjustment process and maintain the long-term stability of the electrical connection.

[0016] The magnetic attraction structure on both sides of the tension box of this utility model supports the series connection of multiple boxes. The combination of magnets and magnetic slots enables rapid assembly, which solves the limitation of insufficient stroke of a single tension box and adapts to the adjustment needs of wire harnesses of different lengths. The dustproof curtain of the wire passage channel is made of flexible silicone material, which allows the wires to pass freely while blocking dust from entering and preventing internal dust accumulation from affecting the operation of the slider and pulley. This modular and protective design expands the applicable scenarios of the device, while reducing maintenance requirements and further extending the service life of the equipment. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0018] Figure 2 This is a front view of the present invention;

[0019] Figure 3 For the present utility model Figure 2 Sectional view of AA in the middle;

[0020] Figure 4 For the present utility model Figure 3 Cross-sectional view of the middle section (BB);

[0021] Figure 5 This is a schematic diagram of the slider structure of this utility model.

[0022] In the diagram: 1. Wire; 2. Connector; 201. Internal thread cap; 3. Tensioning mechanism; 301. Tensioning box; 3011. Damping groove; 3012. Dustproof curtain; 3013. Magnet; 3014. Magnetic groove; 3015. Wire groove; 302. Slider; 3021. Positioning pin; 3022. Roller; 3023. Rotating shaft; 303. Spring; 304. Pulley; 3041. Limiting flange; 3042. Shaft hole. Detailed Implementation

[0023] Please see Figures 1-5 An adaptive tension-adjustable wire harness structure includes a conductor 1 and a connector 2, wherein a tensioning mechanism 3 is provided on the conductor 1;

[0024] The connector 2 is fixedly installed at both ends of the conductor 1. The tensioning mechanism 3 includes a tensioning box 301, a slider 302, a spring 303, and a pulley 304. The upper end face of the tensioning box 301 is provided with two sets of mutually parallel damping grooves 3011. The slider 302 and the spring 303 are installed in the damping grooves 3011 and are slidably connected to the tensioning box 301. The pulley 304 is installed on the slider 302 and is rotatably connected to it. The conductor 1 is wound on the pulley 304 and is slidably connected to it.

[0025] The tension box 301 has screw holes on both sides, and is tensioned and fixed to the surface of the equipment by bolts. The wire 1 is wound in an "S" shape on the two sets of pulleys 304. Under the action of the spring 303, the slider 302 collects the excess wire bundle into the tension box 301, thereby preventing the wire 1 from being too long and sagging, causing the wire 1 to rub against other parts and causing the insulation layer to break, thus improving the service life of the wire bundle.

[0026] Furthermore, the side end face of the slider 302 is provided with a roller 3022 that is rotatably connected thereto, and the side end face of the slider 302 is provided with a positioning post 3021 that cooperates with the spring 303.

[0027] The roller 3022 reduces the friction between the slider 302 and the tension box 301, thereby improving the smoothness of the slider 302's sliding and making its tension adjustment smoother. The spring 303 is sleeved on the positioning post 3021 to prevent the spring 303 from deviating, which would cause uneven force on the slider 302 and jamming, further improving the smoothness of the slider 302.

[0028] Furthermore, the upper end face of the slider 302 is provided with a rotating shaft 3023, the center of the pulley 304 is provided with a shaft hole 3042 that mates with the rotating shaft 3023, and the upper and lower ends of the outer end face of the pulley 304 are provided with limiting flanges 3041.

[0029] The limiting flange 3041 constrains the conductor 1, preventing the conductor 1 from deviating during sliding and causing the tensioning mechanism 3 to lose its tensioning function on the conductor 1, thus improving the stability of the tensioning mechanism 3.

[0030] Furthermore, conductor 1 has a flat structure.

[0031] The flat shape of the wire 1 makes it easy to bend in the horizontal direction, thus facilitating its winding around the two sets of pulleys 304, and it is not easy to bend longitudinally, preventing the wire 1 from falling under its own weight.

[0032] Furthermore, the upper end face of the tension box 301 is provided with a wire threading groove 3015, and the side wall of the wire threading groove 3015 is provided with a dustproof curtain 3012, which is made of silicone material.

[0033] By providing a wire-passing groove 3015 on the upper end face of the tension box 301, it is convenient to wind the wire 1 onto the pulley 304. A dustproof curtain 3012 is provided on the side wall of the wire-passing groove 3015, which can effectively prevent dust from falling into the tension box 301, avoid internal dust accumulation, effectively block the slider 302 and pulley 304, and improve the service life of the equipment.

[0034] Furthermore, a magnet 3013 is provided on the front end face of the tension box 301, and a magnetic groove 3014 corresponding to the position of the magnet 3013 is provided on the back side of the tension box 301.

[0035] The two sets of tensioning boxes 301 can be fixed by the magnet 3013 and the magnetic groove 3014, so that multiple sets of tensioning boxes 301 can be connected in series, avoiding the problem that the tensioning stroke of a single tensioning box 301 is too short and cannot effectively tension the wire 1.

[0036] Furthermore, the outer end face of the connector 2 is provided with a rotatable internal thread cap 201.

[0037] Connector 2 is fixed by internal thread cap 201, which can effectively prevent connector 2 from loosening during the tensioning process of tensioning mechanism 3, and further improve the stability of wire harness.

[0038] When using this wire harness, firstly, connect the connectors 2 at both ends of the wire 1 to the required components. Then, wind the flat wire 1 in an "S" shape around the two sets of pulleys 304. The rollers 3022 on the slider 302 reduce the friction between the wire and the tension box 301, allowing the slider 302 to collect the excess wire into the tension box 301 under the action of the spring 303. At the same time, the limiting flange 3041 on the outer end face of the pulley 304 constrains the wire 1 to prevent it from deviating. The wire is then protected by a silicone dustproof curtain 30 on the side wall of the wire passage 3015. 12. To prevent dust from entering the tension box 301 and affecting the operation of the components, if the tension stroke of a single tension box 301 is insufficient, multiple tension boxes 301 can be connected in series using the magnet 3013 on the front face and the magnetic groove 3014 on the back. The screw holes on both sides of the tension box 301 are fixed to the surface of the equipment by bolts. Finally, the internal thread cap 201 on the outer end face of the rotating connector 2 is rotated to fix it, thus completing the wire harness installation. This achieves automatic adjustment of the tension of the wire 1, avoids the wire 1 from being too long and sagging and getting damaged, and ensures the stable operation of the wire harness.

[0039] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A wire harness structure with adaptive tension adjustment, comprising a conductor (1) and a connector (2), characterized in that: The conductor (1) is provided with a tensioning mechanism (3); The connector (2) is fixedly installed at the front and rear ends of the wire (1). The tensioning mechanism (3) includes a tensioning box (301), a slider (302), a spring (303), and a pulley (304). The upper end face of the tensioning box (301) is provided with two sets of mutually parallel damping grooves (3011). The slider (302) and the spring (303) are installed in the damping grooves (3011) and are slidably connected to the tensioning box (301). The pulley (304) is installed on the slider (302) and is rotatably connected to it. The wire (1) is wound on the pulley (304) and is slidably connected to it.

2. The adaptive tension-adjustable wire harness structure as described in claim 1, characterized in that: The slider (302) has a roller (3022) rotatably connected to its side end face, and a positioning post (3021) that cooperates with the spring (303) is provided on the side end face of the slider (302).

3. The adaptive tension-adjustable wire harness structure as described in claim 1, characterized in that: The upper end face of the slider (302) is provided with a rotating shaft (3023), the center of the pulley (304) is provided with a shaft hole (3042) that cooperates with the rotating shaft (3023), and the upper and lower ends of the outer end face of the pulley (304) are provided with limit flanges (3041).

4. The adaptive tension-adjustable wire harness structure as described in claim 1, characterized in that: The conductor (1) has a flat structure.

5. The adaptive tension-adjustable wire harness structure as described in claim 1, characterized in that: The tension box (301) has a threading groove (3015) on its upper end face, and a dustproof curtain (3012) is provided on the side wall of the threading groove (3015). The dustproof curtain (3012) is made of silicone material.

6. The adaptive tension-adjustable wire harness structure as described in claim 1, characterized in that: The front end of the tension box (301) is provided with a magnet (3013), and the back end of the tension box (301) is provided with a magnetic groove (3014) corresponding to the position of the magnet (3013).

7. The adaptive tension-adjustable wire harness structure as described in claim 1, characterized in that: The outer end face of the connector (2) is provided with a rotatable internal thread cap (201).

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