Cable Harness Wrapping With Protective Flag Mounting
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Solution Overview
Problem
The existing methods for bandaging line sets and attaching holding parts are time-consuming, complex, and difficult to automate due to the interference contour of the line set and the challenges of handling adhesive tape and cable ties, which hinder efficient and cost-effective automated production.
Innovation Solution
A method involving a protective material that forms a flag around the line set, allowing for linear movement and eliminating the need for rotating winding, with the flag serving as a mounting surface for holding parts, which can be welded or glued, reducing cycle times and enabling complete automation of cable protection and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive tape is used for bandaging line sets with rotating movement, then the line set can be wrapped, but the process is very time-consuming and difficult to automate due to the interference contour
Solution Approach 1:
The protective material is divided into two separate protrusions that are turned inside out independently, rather than using continuous rotating wrapping. This segmentation allows for linear movement and automated handling, resolving the contradiction between ease of manufacture and productivity
Solution Approach 2:
Instead of wrapping the adhesive tape around the line set in traditional rotating movement, the patent turns the protrusions of protective material inside out and brings them into contact with each other. This inverted approach eliminates the interference contour problem and enables automation while maintaining ease of bandaging
2Ease of manufacture
If adhesive tape is used to fix holding parts, then the holding part can be attached, but several wraps must be applied requiring mechanical grip and automated adhesive tape handling is very complex
Solution Approach 1:
The patent extracts the adhesive tape handling step entirely from the process. Instead of using adhesive tape to fix the holding part, the protective material itself forms a flag structure that provides a mounting surface for direct attachment, eliminating the complexity of automated adhesive tape handling while maintaining ease of holding part attachment
Solution Approach 2:
The flag made of protective material serves as an intermediary mounting surface between the line set and the holding part. This intermediary structure eliminates the need for complex adhesive tape handling mechanisms while simplifying the attachment process
3Ease of manufacture
If cable ties are used to fix holding parts, then the holding part can be attached, but the narrow cavity of the cable tie must be hit with the counterpart which is very challenging for automated applications
Solution Approach 1:
The patent extracts the cable tie mechanism entirely from the attachment process. The flag made of protective material provides a direct mounting surface that eliminates the need for cable ties, thereby removing the automation challenge of hitting the narrow cavity while maintaining ease of holding part attachment
Solution Approach 2:
The flag serves as an intermediary mounting surface that replaces the cable tie mechanism. This intermediary structure provides a accessible surface for automated attachment methods such as welding or gluing, eliminating the need to hit the narrow cavity of a cable tie
4Ease of manufacture
If rotating movement is used for bandaging, then the line set can be wrapped, but the interference contour makes automation difficult and increases cycle time
Solution Approach 1:
The patent inverts the traditional wrapping approach by turning protrusions inside out instead of rotating wrapping. This eliminates the interference contour issue, enables linear movement for automation, and reduces cycle time while maintaining ease of wrapping
Solution Approach 2:
The protective material is segmented into two protrusions that are turned inside out independently, allowing for efficient linear movement and automated processing. This segmentation reduces the complexity and time of the bandaging process while maintaining ease of wrapping
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
This approach reduces cycle times, enhances economic efficiency, simplifies the assembly process, and minimizes the risk of cable damage by eliminating the need for penetrating the cable harness level, while allowing for modular and scalable automation solutions.
Implementation Method 1
The two protrusions of the protective material are turned inside out, bringing the two protrusions into contact with one another so that the segment of the protective material forms a channel through which the segment of the line set runs
Implementation Method 2
The fastening surface of the holding part is arranged and welded to the flag made of protective material
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A method for bandaging a cable assembly (110) is proposed. Furthermore, a cable assembly (110) bandaged according to this method is proposed, as well as a device (100) for bandaging a cable assembly (110). According to the method, the cable assembly (110) and the protective material (120) are positioned and aligned such that the protective material (120) forms a projection (122) on two opposite sides, transverse to a longitudinal direction of a segment (111) of the cable assembly. The two projections (122) of the protective material (120) are then folded around the segment (111) of the cable assembly, thereby bringing the two projections (122) into contact with each other and surrounding the cable assembly (110) with the protective material (120).The protrusions (122) of the protective material (120) are joined together so that a flag (123) of protective material (120) is formed projecting from the segment (111) of the wiring harness (110), and a retaining part (130) with a mounting surface (133) is arranged on the flag (123) of protective material (120) and welded to the flag (123), the retaining part (130) being designed to be fastened in a vehicle.