Bellows Exterior Material Connection for Modular Wire Harness Lengths
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Solution Overview
Problem
Existing wire harness manufacturing processes face challenges in efficiently connecting exterior materials with different lengths due to the need for multiple fixing operations, leading to increased complexity and cost.
Innovation Solution
The exterior material and connecting body feature alternating first and second uneven regions with specific diameter and length ratios, allowing easy connection and fixation at three points, reducing the number of required parts and operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If multiple tubes with different lengths are combined to match wire harness design size, then the wire harness can be protected with appropriate length, but the manufacturing process requires double operation of fixing the wire harness to both ends of one tube before fixing to the other tube, increasing complexity and time
Solution Approach 1:
The bellows part is divided into multiple modular units, each with standardized connection interfaces. These segmented units can be assembled in series to achieve different total lengths, eliminating the need for complex double-fixing operations while maintaining protection functionality.
Solution Approach 2:
The bellows part is designed with universal connection structures that allow the same modular unit to be used for different length requirements. The standardized interfaces enable multiple units to be connected in various configurations, making the system adaptable to different wire harness lengths without requiring separate custom fixtures or complex assembly procedures.
2Length of moving object
If multiple tubes with different lengths are combined to match wire harness design size, then the wire harness can be protected with appropriate length, but the manufacturing process requires double operation of fixing the wire harness to both ends of one tube before fixing to the other tube, increasing manufacturing time
Solution Approach 1:
The bellows part is divided into multiple modular units, each with standardized connection interfaces. These segmented units can be assembled in series to achieve different total lengths, eliminating the need for complex double-fixing operations while maintaining protection functionality.
Solution Approach 2:
The modular units are pre-assembled with connection interfaces prepared in advance. This preliminary preparation allows for faster final assembly by eliminating the need for complex on-site fixing operations, thereby improving manufacturing efficiency.
3Strength
If exterior materials are connected by overlapping and fixing at multiple points, then connection strength is improved, but the number of required parts and operations increases
Solution Approach 1:
The connection structure merges the overlapping region with the fixing mechanism into an integrated design. The grooves and protrusions are formed as integral features of the bellows part itself, eliminating the need for separate fastening components while maintaining strong connections through the interlocking geometry.
Solution Approach 2:
The bellows part features self-aligning grooves and protrusions that automatically engage during assembly. The connection structure is designed to self-lock through its geometric features, eliminating the need for additional fixing operations or external fastening components while ensuring strong connections.
Data Source
AI summary
An exterior material includes a bellows part that includes ridge parts annularly formed around a center axis along an axial direction and project toward one side in a radial direction intersecting the axial direction, and groove parts annularly formed around the center axis and are recessed toward another side in the radial direction, the ridge parts and the groove parts being alternately aligned along the axial direction, the bellows part being externally attached to a wiring material. The bellows part includes a first uneven region that has one first groove part and two first ridge parts, and a second uneven region that has one second groove part having an outer diameter relatively shorter than an inner diameter of the first groove part, and two second ridge parts having an outer diameter relatively shorter than an inner diameter of the first ridge part.