Cable Harness Carrier Fixation for Automated Connector Assembly
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Solution Overview
Problem
Mounting cable harnesses on carrier modules in vehicles is complex and difficult to automate due to their flexible and complex routing structure, making assembly challenging and inefficient.
Innovation Solution
A cable harness with components temporarily fixed to a flexible carrier using the carrier's material, allowing mobility during assembly, particularly in a plug-in direction, with accessible partial areas for automated assembly, and utilizing retaining tabs and pockets for secure positioning and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cable harnesses are made flexible with complex routing structures to adapt to vehicle installations, then adaptability is improved, but assembly complexity increases and automation becomes difficult
Solution Approach 1:
The cable harness is segmented into modular components (cable sets with integrated connectors) that can be independently handled and assembled. This segmentation reduces the overall assembly complexity while maintaining routing flexibility, as each module can be pre-assembled and tested separately before final installation.
Solution Approach 2:
A temporary fixation mechanism (adhesive tape or retaining clips) is introduced as an intermediary to hold components in position during assembly. This intermediary allows the flexible cable routing to be maintained while providing sufficient stability for automated assembly processes, bridging the gap between flexibility and assembly ease.
2Manufacturing precision
If components are permanently fixed to the cable harness, then positioning precision is improved, but assembly ease deteriorates due to inability to adjust during installation
Solution Approach 1:
The fixation mechanism transitions from static (permanent) to dynamic (temporary/reversible). Components are initially fixed with temporary adhesives or clips that allow for adjustment during assembly, then permanently secured after proper positioning is achieved. This dynamic approach enables both precise positioning and assembly flexibility.
Solution Approach 2:
Components are pre-positioned and temporarily fixed during cable harness assembly, allowing for preliminary alignment and adjustment. The temporary fixation enables workers to make necessary adjustments before final permanent attachment, ensuring both positioning precision and assembly ease.
3Strength
If components are fully covered by carrier material for secure fixation, then fixation strength is improved, but accessibility for automated assembly deteriorates
Solution Approach 1:
The carrier material coverage is applied with local quality variations - fully covering areas requiring secure fixation while leaving exposed areas where components need to be accessed by automated assembly equipment. This selective coverage pattern allows simultaneous achievement of fixation strength and component accessibility.
Solution Approach 2:
Instead of fully covering all components with carrier material, only partial coverage is applied to specific areas where fixation is needed. This partial action approach maintains fixation strength for secured areas while preserving accessibility for areas requiring automated manipulation.
Data Source
Figure 1~2B
Figure 3~4B
Figure 5A~5B
AI summary
The cable harness (2) according to the invention is intended in particular for a vehicle and comprises a plurality of lines (4) which are mounted on a flexible carrier (8), wherein at least one of the lines (4) has an electrical component (6), in particular a contact plug, attached thereto, which is at least temporarily fixed to the carrier (8) by the material of the carrier (8) in such a way that the at least one component (6) is movable during subsequent assembly of the cable harness (2), in particular in a plug-in direction (28) for insertion into an electrical component (26). As a result, the at least one component (6) is fixed in position and accessible for subsequent, in particular automated, final assembly of the cable harness (2), for example on a carrier module, and can, for example, be automatically plugged into a corresponding mating connector.