3D Backshell Harness Flattening With Connector Alignment
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Solution Overview
Problem
Existing CAD software struggles with accurately flattening 3D backshell components, leading to misleading intersections of internal wiring segments with the backshell component, as the flattening process detaches wires from their connectors, causing connectivity issues in 2D representations.
Innovation Solution
A method is developed to maintain connected wiring components in 3D by computing tangents and aligning entry points and tangents during the flattening process, ensuring that route segments remain connected to the backshell component, and displaying the flattened unconnected route segments aligned with the 3D backshell component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all wires are flattened including those associated with connectors, then the flattening process completes for the entire harness, but wires become detached from their connectors and internal wiring segments misleadingly appear to intersect with backshell component
Solution Approach 1:
The patent segments the flattening process into two distinct parts: (1) flattening route segments that are not connected to backshell components, and (2) preserving 3D representation for route segments connected to backshell components. This segmentation allows the system to maintain connectivity accuracy for critical components while still achieving overall harness flattening for manufacturing purposes.
Solution Approach 2:
The patent applies different flattening qualities to different parts of the harness based on their connection status. Route segments connected to backshell components maintain 3D orientation and connectivity information, while unconnected segments are flattened to 2D. This local differentiation ensures that connectivity-critical areas preserve accuracy while non-critical areas achieve flattening efficiency.
2Area of stationary object
If internal wiring segments are flattened through backshell component, then the flattening process covers all areas, but the segments misleadingly appear to intersect with backshell component causing connectivity issues
Solution Approach 1:
The patent maintains 3D spatial information for route segments connected to backshell components even when the overall harness is flattened to 2D. By preserving the third dimension (Z-axis orientation) for critical segments, the system prevents misleading intersections while still providing a flattened view for manufacturing. This selective dimensionality preservation ensures connectivity information is not lost in areas where it matters most.
Data Source
AI summary
A three dimensional (3D) backshell component is flattened to a two dimensional (2D) representation while maintaining a connected wiring component in 3D. Sketch segments for a curved 3D backshell connected first route segment within the backshell housing are stored. A first tangent is computed for a first entry point at a first end point of the connected first route segment, and a flattened route is calculated for route segments unconnected to the backshell. A flattened route position and a second tangent are calculated for a second route segment connected with the first route segment at a second entry point corresponding to the first entry point. The first entry point and the second entry point are aligned, and the first tangent and the second tangent are aligned, and the flattened unconnected route segment aligned with the 3D backshell component is displayed.