3D-Printed Wire Harness Assembly for Automated Spatial Routing
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Solution Overview
Problem
The existing wire harness manufacturing process is complex, low in automation, and costly, with a high defective rate, and is not suitable for the flexible and diversified production needs of modern electrical appliances, particularly requiring a high degree of production automation and the ability to produce spatial 3D structures.
Innovation Solution
A method utilizing 3D printing to manufacture wire harnesses by alternately printing insulation layers and laying conductors, allowing for the creation of complex wire harnesses with high precision and efficiency, including electrical connections and cooling systems, and enabling flexible production of spatial structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional processing and assembly methods are used to manufacture wire harnesses, then the manufacturing process is complex and requires multiple steps (cutting, crimping, bundling), but the degree of automation is low and processing efficiency is low
Solution Approach 1:
The patent combines multiple traditional manufacturing steps (cutting, crimping, bundling, insulation) into a single 3D printing process. The 3D printer integrates functions to simultaneously form conductors, apply insulation layers, and create the final wire harness structure in one automated operation, thereby increasing automation while simplifying the overall process.
Solution Approach 2:
The patent replaces traditional mechanical processing methods (manual or automated cutting, crimping tools, bundling equipment) with a 3D printing system. The 3D printing technology uses additive manufacturing to directly create the wire harness structure layer by layer, substituting complex mechanical operations with a more integrated digital manufacturing process.
2Productivity
If traditional processing and assembly methods are used to manufacture wire harnesses, then various operations can be performed, but processing efficiency is low resulting in high production cost
Solution Approach 1:
The 3D printing process enables continuous manufacturing of wire harnesses without the interruptions between discrete steps (cutting, crimping, bundling) required in traditional methods. The printer continuously deposits material layer by layer to build the complete wire harness structure in an uninterrupted process, significantly improving productivity.
Solution Approach 2:
The 3D printing process performs all necessary manufacturing actions (forming conductors, applying insulation, creating connections) in advance during the single printing operation. The complete wire harness structure is pre-formed with all required features integrated, eliminating the need for subsequent assembly operations.
3Adaptability or versatility
If traditional assembly methods are used to manufacture wire harnesses, then electrical wires can be bundled together, but the production mode is not suitable for small-batch and flexible production
Solution Approach 1:
The 3D printing process allows dynamic adjustment of wire harness designs for different production batches. The manufacturing parameters (conductor layout, insulation thickness, connection points) can be easily modified through digital modeling, enabling flexible production of customized wire harnesses while maintaining efficient manufacturing through automated printing.
4Reliability
If traditional methods are used to manufacture wire harnesses, then electrical wires can be processed and assembled, but the defective rate is high
Solution Approach 1:
The patent replaces multiple mechanical operations (cutting, crimping, manual assembly) that are prone to human error and variability with a single 3D printing process. The automated printing system ensures consistent material deposition, precise positioning, and uniform insulation application, reducing defects while consolidating the complex manufacturing steps into one controlled process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, reduces costs, and improves the quality and efficiency of wire harness production, enabling rapid and automated production of complex wire harnesses with reduced assembly time and material usage, while accommodating diverse electrical appliance requirements.
Implementation Method 1
printing an insulation carrier by a 3D printing process; printing an insulation layer on the insulation carrier by a 3D printing process
Data Source
AI summary
A method for manufacturing a wire harness, and a wire harness. The method includes: Step S110: printing an insulation carrier by a 3D printing process; Step S120: laying at least one conductor on the insulation carrier; and Step S130: printing an insulation layer on the insulation carrier by a 3D printing process, to make the conductor be enclosed between the insulation carrier and the insulation layer. The wire harness is manufactured by the method for manufacturing the wire harness. The present disclosure provides a method for manufacturing wire harness by means of 3D printing, in which a wire harness can be obtained by printing an insulation layer and laying a conductor alternatively.