Vehicle Cable Binder Assembly With Poka-Yoke Anti-Rotation Mounting
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Solution Overview
Problem
Existing cable binders for vehicles, particularly in vehicle lamps, suffer from instability and incorrect mounting, leading to cable damage due to loose attachment and multiple possible orientations, which can result in unintended cable movement and damage.
Innovation Solution
A cable binder with a mounting protrusion featuring a tapered section and poka-yoke elements ensures secure attachment by allowing insertion in only one orientation, preventing rotation and extraction, using a slit for elastic deformation during insertion, and incorporating grooves and ribs to stabilize the cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a standard zip tie binder with cylindrical opening is used for mounting to a metallic pin, then the binder can be easily installed, but it can move or rotate on the pin and become loose over time
Solution Approach 1:
The mounting protrusion features an asymmetric tapered section with a specific angle (30-60 degrees) that creates a directional insertion path. This asymmetric geometry prevents rotation and ensures the binder can only be mounted in the correct orientation, eliminating the problem of movement and loosening over time while maintaining easy installation through the tapered guidance
2Adaptability or versatility
If a binder with cylindrical opening is used, then the binder can be mounted in multiple orientations, but this allows cables to be fixed in wrong positions or directions leading to damage
Solution Approach 1:
The tapered section creates an asymmetric mounting interface that accepts insertion from only one orientation. The taper angle and geometry are designed to guide the binder into the correct position while physically preventing insertion in wrong orientations, thus ensuring cable positioning accuracy without compromising the mounting process
3Device complexity
If a binder body is made from one piece of material with the zip tie, then the structure is simple, but the binder is not securely fixed to the pin and can rotate around it
Solution Approach 1:
The one-piece binder structure incorporates an asymmetric tapered mounting protrusion that, while maintaining structural simplicity, creates a directional fit with the mounting opening. This asymmetric geometry prevents rotation and ensures stable attachment without requiring complex multi-part constructions
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
The solution provides stable cable positioning, reducing damage and noise by ensuring cables remain in the intended direction, enhancing durability and security.
Implementation Method 1
The mounting protrusion comprises a slit dividing the mounting protrusion into at least two mounting protrusion parts along at least part of the mounting protrusion's length. The mounting protrusion parts can then be flexible such that they can be moved closer together across the slit when pressed from the sides, which occurs during insertion into an appropriately sized opening
Data Source
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AI summary
Cable binder for vehicles, cable-binding assembly comprising the binder, and vehicle lamp with the assembly. The binder comprises a body (1) for attachment to a vehicle component, and a strip (2) for binding cables (3). The strip (2) can be closed into a loop (4) for binding the cables (3) using a securing mechanism. The body (1) comprises a mounting protrusion (6) for insertion into an opening (5) in a wall (10) of the component. The mounting protrusion (6) comprises a poka-yoke element (8) for engaging with a complementary poka-yoke element (8) in the opening (5). The mounting protrusion (6) is tapered to facilitate insertion into the opening (5), and its tapered section (7) is ended by a back surface (9) for bracing against the wall (10) after the insertion is done. The mounting protrusion (6) further comprises a slit (17) dividing the mounting protrusion (6) into at least two parts.