Appliance door assembly
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Solution Overview
Problem
The existing methods for assembling appliance doors with integrated electronic devices are inefficient, often requiring two individuals to mount and connect the door to the cabinet, or are cumbersome for a single assembler who must hold the door while making electrical connections.
Innovation Solution
A wire cover that rotates about the hinge axis, allowing for secure mounting of the door to the cabinet before forming electrical connections, thereby eliminating the need for the assembler to hold the door during connection and simplifying the assembly process by allowing a single technician to manage the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the door is mounted to the cabinet before making electrical connections, then the door can be securely mounted and the weight is carried by the cabinet, but the electrical connectors must be accessible during mounting which complicates the structure
Solution Approach 1:
The wire cover is divided into a first portion and a second portion that can rotate relative to each other about the hinge axis. The first portion covers the wire harness, while the second portion provides connector access. This segmentation allows the cover to serve multiple functions at different stages of assembly without requiring complex additional structures.
Solution Approach 2:
The wire cover is designed to be rotatable about the hinge axis, transitioning between a first position during assembly where connectors are accessible, and a second operational position where connectors are protected. This dynamic positioning allows the same structure to serve different purposes during different phases of the product lifecycle.
2Productivity
If a single assembler performs both door mounting and electrical connection, then labor cost is reduced, but the assembler must hold the door during connection which is cumbersome
Solution Approach 1:
The door is mounted to the cabinet before the electrical connectors are connected. The wire cover is positioned in its first position during this mounting phase, allowing connectors to be accessible. This preliminary mounting action allows the door to be securely supported by the cabinet before the connection step, eliminating the need for the assembler to hold the door.
Solution Approach 2:
The wire cover acts as an intermediary mechanism that facilitates single-assembler operation. By being rotatable and positionable, it allows the assembler to work on electrical connections after the door is mounted, without needing to support the door weight, thus enabling one person to perform both mounting and connection tasks efficiently.
3Ease of operation
If the wire harness is exposed during door operation, then connection is easier, but the wire harness is subject to fatigue from pulling, moving, and twisting
Solution Approach 1:
The wire harness is extracted from direct exposure by being enclosed within the wire cover. The cover protects the wire harness from the pulling, moving, and twisting forces generated during door operation, while still allowing the connectors to be accessed when needed by rotating the cover to the first position.
Solution Approach 2:
The wire cover acts as a flexible protective shell that encloses the wire harness. It can rotate about the hinge axis to provide access when needed, but otherwise maintains coverage to protect the wire harness from mechanical damage during normal door operation.
4Ease of operation
If the wire cover remains in the exposed position, then connectors are always accessible, but the wire harness is unprotected from damage
Solution Approach 1:
The wire cover is designed to be rotatable about the hinge axis, transitioning between a first position during assembly where connectors are accessible, and a second operational position where connectors are protected. This dynamic positioning allows the same structure to serve different purposes during different phases of the product lifecycle.
Data Source
AI summary
A laundry appliance door assembly with a wire cover to protect the wire conductor that passes through the door hinge where it has a tendency to get pulled and damaged when the door is in motion. The wire cover includes a wire cover and a wire conduit coaxially connected together allowing the wire cover to rotate relative to the wiring conduit while within alignment of the hinge rotational axis. The wire cover comprises two lateral halves for ease of installation where it is designed to encase the wire conductor that passes through the door hinge.