Vehicle Cable Harness Grommet Layout for Automated Firewall Routing
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Solution Overview
Problem
The assembly of vehicle components is complicated by the need to route numerous cables across the vehicle, requiring manual intervention and adaptation of frame parts, which increases costs and hinders automation, particularly in vehicles with different drive configurations.
Innovation Solution
An assembly featuring a centrally located opening in a partition wall for a cable harness, utilizing a grommet to facilitate easy routing and secure attachment, allowing for a one-piece wiring harness that simplifies installation and reduces manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual cable routing through frame openings is used, then cable connection is achieved, but assembly complexity and labor requirements increase
Solution Approach 1:
The cable harness is divided into multiple sections with individual cable bundles grouped by function or destination. Each bundle is independently routed through separate openings in the frame, allowing parallel assembly operations and reducing the complexity of routing a single large harness through multiple openings sequentially
Solution Approach 2:
A cable guide structure with integrated openings and routing channels is introduced as an intermediary component. This guide structure pre-organizes the cable paths and provides structured access points, transforming the complex task of manual cable routing into a simpler process of inserting cables into pre-defined channels
2Extent of automation
If manual cable pulling is performed, then cable installation is completed, but automation capability is reduced
Solution Approach 1:
The cable harness sections are pre-assembled and pre-routed through the frame openings before the final assembly stage. Cables are pre-attached to connectors and pre-positioned within the cable guide structure, transforming the complex manual pulling operation into a simple insertion task that can be performed by automated placement equipment
Solution Approach 2:
The manual mechanical pulling operation is replaced by automated placement systems that use robotic manipulators to position and insert pre-prepared cable sections. The structured openings and guide channels provide physical constraints that enable robotic accuracy without requiring complex force application or manipulation
3Adaptability or versatility
If frame openings are adapted for different drive configurations, then cable routing flexibility is improved, but manufacturing costs increase
Solution Approach 1:
The frame opening structure is designed with universal characteristics that accommodate multiple drive configurations. Standardized opening positions and dimensions are used across all vehicle variants, with the cable guide structure providing the necessary routing flexibility through adjustable channels and multiple path options within the same physical opening architecture
Solution Approach 2:
The cable routing system incorporates dynamic adaptability through adjustable cable guides and reconfigurable routing channels within the frame openings. The physical opening structure remains fixed and standardized, while the internal routing elements can be repositioned or reconfigured to accommodate different drive layouts without requiring custom openings for each configuration
Data Source
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AI summary
The invention relates to an assembly (1) for a wiring connection between a vehicle interior (11) and an engine compartment (12) of a vehicle (10), comprising: - a partition (100) designed to be arranged between the vehicle interior (11) and the engine compartment (12), - a wiring harness (200) designed to electrically connect a plurality of vehicle electrical system components (10) to one another, - a grommet (300) connected to the wiring harness (200), wherein the partition (100) has a central opening (130) in a transverse direction (17) of the vehicle (10) in which the grommet (300) is arranged. The invention further relates to a vehicle and a method for creating a wiring connection.